Battery cell support assembly with integrated thermal event mitigation

Abstract

A multi-cell rechargeable energy storage system (RESS) includes battery cells, where each of the battery cells has a respective cell vent configured to exhaust gas. The cell holder is configured to support a battery cell and includes a holder body defining apertures arranged in rows. Each aperture is configured to align with and in fluid communication with a cell vent of one of the battery cells. Thermal event passages are located proximate the cell support, where each thermal event passage extends parallel to a respective row of apertures. A fill material at least partially surrounds the battery cells and a sensor assembly is in each of the thermal event pathways.

Description

Technical Field

[0001] This disclosure relates to a battery cell support assembly with integrated thermal runaway mitigation for a multi-cell rechargeable energy storage system (RESS). Background Technology

[0002] Typically, a battery system for generating and storing electrical energy comprises one or more battery cells for providing power to a load. These battery cells can be arranged close together to form battery cell arrays or systems, such as battery modules, clusters, etc.

[0003] Battery cells can be used to store electrical energy for future use and as a buffer between peak power generation and peak system load, such as in stationary energy storage systems and electric vehicles (EVs). The chemistry of rechargeable batteries, along with external factors, can lead to internal reaction rates that generate a significant amount of heat. Exposure of a battery cell to elevated temperatures over an extended period can cause the cell to experience thermal events. Heat buildup in one cell can cause heat to diffuse or propagate to adjacent cells, thus affecting the entire battery array. Summary of the Invention

[0004] A multi-cell rechargeable energy storage system (RESS) is disclosed herein. The RESS includes battery cells, each of which has a corresponding cell vent configured to vent gases. A cell support is configured to support the battery cells and includes a support body defining a row of orifices. Each orifice is configured to align with and fluidly communicate with a cell vent in one of the battery cells. Thermal event paths are located near the cell support, each thermal event path extending parallel to a corresponding row of orifices. Filling material at least partially surrounds the battery cells, and sensor assemblies are located in each of the thermal event paths.

[0005] Another aspect of this disclosure may include an RESS closure having a tray and a mating cap, wherein the RESS closure is configured to receive a battery cell, a cell support, filling material, and a sensor assembly.

[0006] Another aspect of this disclosure is that the sensor assembly includes a dielectric sensor assembly.

[0007] Another aspect of this disclosure may be the length of each corresponding row of the dielectric sensor assembly extension hole.

[0008] Another aspect of this disclosure is that the sensor assembly includes a sensor aligned with the corresponding hole.

[0009] Another aspect of this disclosure is that the sensor includes a capacitive sensor.

[0010] Another aspect of this disclosure is that the sensor includes a temperature sensor.

[0011] Another aspect of this disclosure is that the sensor assembly includes at least one transmitter and at least one receiver configured to receive signals from the at least one transmitter.

[0012] Another aspect of this disclosure is that at least one transmitter is located near a first end of a corresponding one of the thermal event channels, and at least one receiver is located near a second end of a corresponding one of the thermal event channels.

[0013] Another aspect of this disclosure is that the transmitter includes one of an infrared transmitter, an ultrasonic transmitter, or a laser beam transmitter.

[0014] Another aspect of this disclosure is that the sensor assembly is overmolded using a unit support.

[0015] Another aspect of this disclosure is that the sensor assembly is attached to the unit bracket using an adhesive.

[0016] A motor vehicle is disclosed herein. The motor vehicle includes a power source configured to generate power source torque, and a multi-cell rechargeable energy storage system (RESS) configured to supply electrical energy to the power source. The RESS includes battery cells, wherein each of the battery cells has a corresponding cell vent configured to exhaust gases. A cell support is configured to support the battery cells and has a support body defining rows of orifices. Each orifice is configured to align with and fluidly communicate with a cell vent in one of the battery cells. Thermal event paths are located near the cell support, wherein each thermal event path extends parallel to a corresponding row of orifices. Filling material at least partially surrounds the battery cells, and sensor assemblies are located in each of the thermal event paths.

[0017] A method for assembling a multi-cell rechargeable energy storage system (RESS) is disclosed herein. The method includes positioning battery cells near a cell support configured to support the battery cells and having a support body defining rows of orifices. Each orifice is configured to align with and fluidly communicate with a cell vent in one of the battery cells. The method further includes positioning sensor assemblies within each of thermal event paths, wherein each of the thermal event paths extends parallel to a corresponding row of orifices. The method also includes sealing the battery cells using an RESS closure. The RESS closure includes a tray and a mating cap and is configured to receive the battery cells, the cell support, and the sensor assemblies.

[0018] Another aspect of this disclosure is that the sensor assembly includes sensors, each of which is aligned with a corresponding aperture.

[0019] Another aspect of this disclosure is that the sensor assembly includes a transmitter and a receiver configured to receive signals from the transmitter. Option 1. A multi-cell rechargeable energy storage system (RESS), comprising: Multiple battery cells, wherein each battery cell includes a corresponding cell vent configured to exhaust gas; A unit support, the unit support being configured to support the plurality of battery units and having a support body having a plurality of holes arranged in a row, wherein each hole is configured to be aligned with and in fluid communication with a unit vent of one of the plurality of battery units; Multiple thermal event paths are located near the unit support, wherein each thermal event path extends parallel to a corresponding row of holes in the plurality of holes; Filling material, said filling material at least partially surrounding said plurality of battery cells; and A sensor assembly located in each of the plurality of thermal event pathways. Option 2. The multi-cell RESS according to Option 1 includes an RESS closure having a tray and a mating cap, wherein the RESS closure is configured to accommodate the plurality of battery cells, cell supports, filling material and sensor assemblies. Option 3. The multi-unit RESS according to Option 1, wherein the sensor assembly includes a dielectric sensor assembly. Option 4. The multi-unit RESS according to Option 3, wherein the dielectric sensor assembly extends the length of each corresponding row of holes in the plurality of holes. Option 5. The multi-unit RESS according to Option 1, wherein the sensor assembly includes a plurality of sensors, wherein each of the plurality of sensors is aligned with a corresponding hole in the plurality of holes. Option 6. The multi-unit RESS according to Option 5, wherein the multiple sensors include multiple capacitive sensors. Option 7. The multi-unit RESS according to Option 5, wherein the multiple sensors include multiple temperature sensors. Option 8. The multi-unit RESS according to Option 1, wherein the sensor assembly includes at least one transmitter and at least one receiver configured to receive signals from the at least one transmitter. Option 9. The multi-unit RESS according to Option 8, wherein at least one transmitter is located near a first end of a corresponding one of the plurality of thermal event channels, and at least one receiver is located near a second end of a corresponding one of the plurality of thermal event channels. Option 10. The multi-unit RESS according to Option 9, wherein the transmitter includes one of an infrared transmitter, an ultrasonic transmitter, or a laser beam transmitter. Option 11. The multi-unit RESS according to Option 1, wherein the sensor assembly is encapsulated using a unit bracket. Option 12. The multi-unit RESS according to Option 1, wherein the sensor assembly is attached to the unit support using an adhesive. Option 13. A motor vehicle, comprising: A power source configured to generate power source torque; and A multi-cell rechargeable energy storage system (RESS) configured to supply electrical energy to a power source, the RSS comprising: Multiple battery cells, wherein each battery cell includes a corresponding cell vent configured to exhaust gas; A unit support, the unit support being configured to support the plurality of battery units and having a support body having a plurality of holes arranged in a row, wherein each hole is configured to be aligned with and in fluid communication with a unit vent of one of the plurality of battery units; Multiple thermal event paths are located near the unit support, wherein each thermal event path extends parallel to a corresponding row of holes in the plurality of holes; Filling material, said filling material at least partially surrounding said plurality of battery cells; and A sensor assembly located in each of the plurality of thermal event pathways. Option 14. The motor vehicle according to Option 13 includes an RESS closure having a tray and a mating cover, wherein the RESS closure is configured to accommodate the plurality of battery cells, cell supports, filling material and sensor assemblies. Option 15. The motor vehicle according to Option 13, wherein the sensor assembly includes a dielectric sensor assembly that extends the length of each corresponding row of holes in the plurality of holes. Option 16. The motor vehicle according to Option 13, wherein the sensor assembly includes a plurality of sensors, wherein each of the plurality of sensors is aligned with a corresponding hole in the plurality of holes. Option 17. The motor vehicle according to Option 13, wherein the sensor assembly includes at least one transmitter and at least one receiver configured to receive signals from the at least one transmitter. Option 18. A method for assembling a multi-cell rechargeable energy storage system (RESS), the method comprising: Multiple battery cells are positioned near a cell support, the cell support being configured to support the multiple battery cells and having a support body defining a plurality of holes arranged in a row, wherein each hole is configured to be aligned with and in fluid communication with a cell vent of one of the multiple battery cells; The sensor assembly is positioned within each of a plurality of thermal event paths, wherein each of the plurality of thermal event paths extends parallel to a corresponding row of holes in the plurality of holes; and The plurality of battery cells are enclosed using an RESS enclosure, which includes a tray and a mating cap, wherein the RESS enclosure is configured to accommodate the plurality of battery cells, cell supports, and sensor assemblies. Option 19. The method according to Option 18, wherein the sensor assembly includes a plurality of sensors, wherein each of the plurality of sensors is aligned with a corresponding hole in the plurality of holes. Option 20. The method according to Option 19, wherein the sensor assembly includes a transmitter and a receiver configured to receive signals from the transmitter. Attached Figure Description

[0020] Figure 1 This is a schematic top view of an embodiment of a motor vehicle employing multiple power sources and a multi-cell rechargeable energy storage system (RESS) configured to generate and store electrical energy used by a vehicle system including the power sources.

[0021] Figure 2 yes Figure 1 The schematic side view of the RESS shown illustrates battery cells arranged within a battery system enclosure with a tray and a cover.

[0022] Figure 3 Based on this disclosure Figure 1 The enlarged schematic plan view of the RESS shown in the figure illustrates battery cells arranged in rows on a cell support assembly with thermal runaway mitigation.

[0023] Figure 4 It is based on the provisions of this disclosure. Figure 3 The cross-sectional view taken by line 4-4 illustrates an example sensor assembly within the path.

[0024] Figure 5 It is based on the provisions of this disclosure. Figure 3 The cross-sectional view taken by line 5-5 illustrates another example sensor assembly within the path.

[0025] Figure 6 It is based on the provisions of this disclosure. Figure 3 The cross-sectional view taken by line 6-6 illustrates another example sensor assembly within the path.

[0026] Figure 7 The diagram illustrates the detection method according to this disclosure. Figure 1 Methods for addressing intrusive substances in the pathway of RESS. Detailed Implementation

[0027] Those skilled in the art will recognize that the descriptive use of terms such as “above,” “below,” “upward,” “downward,” “top,” “bottom,” “left,” and “right” in the figures does not constitute a limitation on the scope of this disclosure as defined by the appended claims. Furthermore, this teaching may be described herein in accordance with functional and / or logical block components and / or various processing steps. It should be understood that such block components may include multiple hardware, software, and / or firmware components configured to perform the specified function.

[0028] Reference Figure 1 This describes a motor vehicle 10 having a powertrain 12. Vehicle 10 may include, but is not limited to, commercial vehicles, industrial vehicles, passenger vehicles, aircraft, boats, trains, or the like. It is also contemplated that vehicle 10 may be a mobile platform (such as an aircraft, all-terrain vehicle (ATV), boat, personal mobility device, robot, and the like) to achieve the purposes of this disclosure. The powertrain 12 includes a power source 14 configured to generate power source torque for propelling vehicle 10 relative to a road surface 18 via drive wheels 16. Power source 14 is depicted as an electric motor-generator.

[0029] like Figure 1 As shown, the powertrain 12 may also include an additional power source 20, such as an internal combustion engine. Power sources 14 and 20 can work together to provide power to the vehicle 10. The vehicle 10 also includes an electronic controller 22 and a multi-unit rechargeable energy storage system (RESS) 24 configured to generate and store electrical energy through a thermogenetic electrochemical reaction to provide electrical energy to power sources 14 and 20. The electronic controller 22 may be a central processing unit (CPU) that regulates various functions on the vehicle 10, or a powertrain control module (PCM) configured to control the powertrain 12 to generate a predetermined amount of power source torque. The RESS 24 may be connected to power sources 14 and 20, the electronic controller 22, and other vehicle systems via a high-voltage bus 25.

[0030] RESS24 includes multiple battery cells 28, which can be subdivided into battery groups or modules (shown as modules 26-1 and 26-2) and / or organized into battery packs 27. Figure 2As shown, the battery cells 28 in each module of RESS24 (such as modules 26-1 and 26-2 shown) are arranged in separate adjacent rows, such as the first row 30-1, the adjacent (directly adjacent) second row 30-2, and the third and fourth rows 30-3 and 30-4. As shown, each battery cell 28 in rows 30-1, 30-2, 30-3, and 30-4 can be configured as a cylindrical or prismatic cell, generally extending upward in the XZ plane. Although two modules 26-1 and 26-2 are shown, with four rows 30-1, 30-2, 30-3, and 30-4 of battery cells 28 in each module, this does not preclude RESS24 from having more or fewer of these modules and rows. The remainder of this specification will focus on the module construction of four rows 30-1, 30-2, 30-3, and 30-4 of battery cells 28, which can be applied to a particular battery module with a desired total number of cells.

[0031] like Figure 2 As shown, RESS 24 also includes a battery pack or RESS enclosure 32 surrounded by an surrounding environment 34 (i.e., the environment outside the RESS enclosure). The battery pack enclosure 32 is configured to accommodate each row 30-1, 30-2, 30-3, 30-4 of battery cells 28 in the respective modules 26-1, 26-2, and includes a lower enclosure portion with an enclosure tray 32-1 and an upper portion with a matching enclosure cover 32-2. Figure 2 (As shown in the diagram). The closure cover 32-2 is configured to engage with the closure tray 32-1 to substantially seal the RESS closure 32 and its contents from the surrounding environment 34. As shown, the RESS closure 32 is arranged in a horizontal XY plane such that, when viewed along the z-axis, the closure cover 32-2 is positioned above the closure tray 32-1.

[0032] like Figure 3-6 As shown, each battery cell 28 generally includes an electrical terminal 28A and a corresponding cell vent 28B configured to discharge or release high-pressure gas 36. This gas 36 can be generated within the battery cell 28 as a byproduct of thermal events within the battery cell 28.

[0033] Generally, during normal operation of RESS24, the cooling within RESS24 effectively absorbs the heat energy released by battery cell 28. However, during extreme conditions, such as during thermal events (via... Figure 4-6(Identified by reference numeral 40 in the accompanying drawings), the amount of heat energy released by a cell 28 experiencing a thermal event may exceed the capacity of the RESS 24 to effectively transfer heat (e.g., from the RESS enclosure 32 to the surrounding environment 34). Therefore, the excess heat energy will typically be transferred between adjacent cell 28s and between adjacent cell modules 26, causing the thermal event to propagate through the RESS 24. The term "thermal event" broadly refers to an uncontrolled rise in temperature in one cell 28 that, if uncontrolled, may propagate and spread through other cell 28s. During a thermal event, heat generation within the battery system or cell exceeds heat dissipation, thus causing a further rise in temperature. Thermal events can be triggered by various conditions, including short circuits within the cell, improper cell use, physical abuse, manufacturing defects, or exposure of the cell to extreme external temperatures.

[0034] For example, in the event that one or more battery cells 28 in a battery module 26 experience a thermal event 40, the excess gas 36 generated during such an event can cause a highly elevated internal cell pressure with a tendency to break open the corresponding cell vent 28B. In the event of such gas discharge, the discharged high-temperature gas 36 (with temperatures up to 1500 degrees Celsius) can also transport cell fragments through the closure 32, thereby triggering heat propagation to other adjacent battery cells 28 and the cell module 26. Therefore, this transmission of high-temperature gas 36 generally increases the likelihood of a chain reaction affecting significant portions of the RESS 24.

[0035] like Figure 3-6 As shown, RESS 24 also includes a cell support assembly 42 with thermal event mitigation features disposed within the closure 32. Although not shown, the closure 32 may also include a cell support structure arranged close to the battery terminals 28A for the overall stability of the assembled battery cells 28. The cell support assembly 42 includes a cell holder 44 having a body portion configured to support (e.g., position and hold) the battery cell 28. The cell holder 44 may be made of glass-filled nylon capable of forming a rigid and stable cell holder structure or another high-temperature resistant and tough material. The cell holder 44 includes a holder body defining a plurality of holes 46 arranged in rows 48. When the battery cells 28 are mounted in the cell holder 44, rows 30-1, 30-2, 30-3, 30-4 of the battery cells are arranged in and coincide with the rows 48 of the corresponding cell holders, such that each hole 46 is aligned with and in fluid communication with a cell vent 28B of one of the assembled battery cells 28.

[0036] like Figure 3As shown, the unit support 44 can be configured to engage and fit (e.g., embed) with the closure tray 32-1. Specifically, as shown, the closure tray 32-1 may include a plurality of channels 54, and the unit support 44 may include a plurality of integral protrusions or partition portions 56. Each protrusion portion 56 of the unit support can be configured to engage one of the closure tray channels 54, thereby establishing a plurality of longitudinal thermal event pathways 58. This is such that each pathway 58 may be below at least one of the rows 48 of the holes 46 and extend along at least one of the rows 48 of the holes 46. Figure 4-6 The RESS24 may also include an adhesive disposed in the closure tray channel 54 between the closure tray 32-1 and the corresponding support protrusion 56, thereby securing the unit support assembly 42 to the closure tray.

[0037] During the assembly of RESS 24, a filling material 55 is added to surround the battery cell 28. In one example, the filling material 55 is added as a liquid material (such as resin), which expands to fill the gap between the battery cell 28 and the mating cap 32-2. As the filling material 55 expands within RESS 24, air within RESS 24 is removed. To prevent the formation of areas with high-pressure air in the RESS, the cell support 44 includes an air escape passage 64. Figure 4-5 This fluidly connects the first side of the supporting battery cell 28 of the cell holder 44 to the second side of the cell holder 44 near the passage 58. In the illustrated example, the air escape passage 64 employs a meandering path having a series of straight segments connected by bends or curves. The air escape passage 64 can be formed by a series of overlapping joints and mica sheets in the plastic features, such that the mica acts as a thermal event barrier. The air escape passage 64 is also located between adjacent cells 28 and is in fluid communication with the passage 58 to utilize the purpose of the passage 58 for allowing removed air to escape from the RESS 24 during assembly.

[0038] like Figure 4As shown, each of the passages 58 may also include a sensor assembly, such as at least one of sensor assemblies 60A, 60B, 60C, or 60D. While the illustrated example shows four different sensor assemblies in RESS 24, RESS 24 may include a single type of sensor assembly for each of the passages 58 or different sensor assemblies between separate passages 58. Sensor assemblies 60A, 60B, 60C, and 60D help detect thermal events in individual units 28 or rows 30 of units 28 in RESS 24, as described in more detail below. Additionally, sensor assemblies 60A, 60B, 60C, and 60D can detect the presence of material protruding into the passages 58, such as filler material 55, as discussed in more detail below. Sensor assemblies 60A, 60B, 60C, and 60D may be overmolded using unit holder 44, attached to unit holder 44 using adhesive, or heat-fused to unit holder 44.

[0039] like Figure 3 As shown, sensor assembly 60A includes a dielectric sensor assembly having a pair of electrodes 70 supported in a substrate material 72. During operation of sensor assembly 60A, each of the electrodes 70 operates at a different voltage to generate a non-uniform electric field. When filler material 55 is mounted into RESS 24, filler material 55 can expand into areas of RESS 24 outside the area surrounding cell 28, such as into passage 58. If filler material 55 expands into passage 58, it will interact with the electric field generated by the electrodes 70. This interaction can cause a change in capacitance detected by the circuitry of sensor assembly 60A. When a change in capacitance is detected by sensor assembly 60A, an alarm can be triggered to indicate that filler material 55 may have intruded into passage 58. If filler material 55 obstructs passage 58 beyond a predetermined cross-sectional area of ​​passage 58, filler material 55 can be removed from passage 58.

[0040] like Figure 3-4 As shown, one of the passages 58 in RESS 24 may also include a sensor assembly 60B. A feature of sensor assembly 60B is that a sensor 74 is associated with each individual cell 28 and is located near a corresponding hole 46 in the cell holder 44. This allows sensor assembly 60B to identify the presence of filling material 55 or a thermal event 40, accurate to a single cell 28. Sensor 74 may include one or more of the following near each hole 46: a capacitive sensor, a temperature sensor, a pair of electrodes, a current leakage sensor, or a liquid sensor.

[0041] When sensor 74 includes a capacitive sensor, sensor assembly 60B is able to detect both the presence of filling material 55 in passage 58 and a thermal event 40 occurring in individual unit 28. Sensor 74 may include two electrodes separated from each other by a dielectric material (such as air or a dielectric substrate). When an object or material approaches or contacts this type of sensor 74, it alters the dielectric properties between the electrodes, resulting in a change in capacitance. The circuitry of sensor assembly 60B can measure the change in capacitance by monitoring the current flowing through one of the electrodes or by observing a change in the alternating current flowing through them. If detected after filling material 55 has been installed into RESS 24, the change in capacitance can trigger an alarm indicating that filling material 55 may have entered passage 58.

[0042] Furthermore, if the change in capacitance determined by sensor assembly 60B occurs during the use of RESS 24, this can indicate that a thermal event 40 has occurred in the corresponding cell 28. The thermal event 40 can be detected by gas 36 leaving cell 28 and entering passage 58 through hole 46, or by other debris entering passage 58 near sensor 74 from within cell 28.

[0043] When sensor 74 includes a temperature sensor, sensor assembly 60B is able to detect both the presence of filling material 55 in passage 58 and a thermal event 40 occurring in individual unit 28. When filling material 55 is installed in RESS 24, it generates an exothermic reaction as it expands and solidifies. If filling material 55 reaches within a predetermined distance of one of the temperature sensors, sensor assembly 60B can trigger an alarm indicating that filling material 55 may have entered passage 58.

[0044] Furthermore, the temperature sensor in sensor assembly 60B can identify thermal event 40 by measuring temperature changes within passage 58. If the change is determined to exceed a predetermined threshold, it can indicate that the corresponding unit 28 has experienced thermal event 40. This is due to the extreme temperature of the gas 36 leaving unit 28, as discussed above.

[0045] When sensor 74 includes a pair of electrodes, sensor assembly 60B is capable of detecting both the presence of filling material 55 in passage 58 and a thermal event 40 occurring in individual unit 28. Sensor 74 may include a pair of electrodes that sense leakage current between the electrodes caused by the conductivity of the filling material 55 located close to the electrodes. Sensor assembly 60B can trigger an alarm for the possibility of filling material 55 intruding into passage 58. Similarly, the pair of electrodes can sense gas 36 or debris entering the passage from within unit 28 during thermal event 40, and sensor assembly 60B can trigger an alarm for the possible thermal event 40.

[0046] For an example of a sensor 74 including a liquid sensor, sensor assembly 60B can detect both the presence of filling material 55 in passage 58 and a thermal event 40 occurring in individual unit 28. Sensor 74 may include a liquid-absorbing membrane that can expand in the presence of liquid, resulting in an electrical response detectable by sensor assembly 60B. If liquid is detected when filling material 55 is being installed in RESS 24, it can indicate that filling material 55 has entered passage 58 and trigger an alarm. Similarly, the liquid sensor can detect the presence of liquid discharged from unit 28 during thermal event 40, and sensor assembly 60B can trigger an alarm for possible thermal event 40.

[0047] like Figure 3 and 5 As shown, sensor assembly 60C can detect both the presence of filling material 55 in passage 58 and a thermal event 40 occurring within a row of unit 28. In the illustrated example, sensor assembly 60C includes a transmitter 80 that generates electromagnetic radiation (such as infrared light, ultrasonic waves, or laser beams) detected by receiver 82, which is configured to detect the corresponding type of electromagnetic radiation. In the illustrated example, transmitter 80 is located at a first end of passage 58, and receiver 82 is located at a second opposite end of passage 58, such that electromagnetic radiation will pass through each of the holes 46 in row 30 of unit 28. Because sensor assembly 60C observes the entire row 30 of unit 28 at a given time, sensor assembly 60C can detect events occurring across the entire row 30 of unit 28.

[0048] For example, receiver 82 can sense an interruption in electromagnetic radiation 84 from transmitter 80. If detected during the filling of filling material 55 into RESS 24, this interruption in electromagnetic radiation 84 indicates that filling material 55 has entered passage 58, and sensor assembly 60C can trigger an alarm. Similarly, if sensor assembly 60C detects an interruption in electromagnetic radiation 85 received by receiver 82 during operation of RESS 24, it can indicate the presence of gas 36 or debris entering passage 58 during thermal event 40 and trigger a corresponding alarm.

[0049] like Figure 3 and 6As shown, sensor assembly 60D can detect both the presence of filling material 55 in passage 58 and a thermal event 40 occurring within a row of cell 28. In the illustrated example, sensor assembly 60D includes a combined transmitter / receiver 86 that both generates electromagnetic radiation 88 (such as infrared light, ultrasonic waves, or laser beams) and detects electromagnetic radiation 88 reflected backward toward the combined transmitter / receiver 86 in passage 58. In the illustrated example, the combined transmitter / receiver 86 is located at a first end of passage 58 and can emit electromagnetic radiation 88 along passage 58 and through each of the holes 46 in row 30 of cell 28. Because sensor assembly 60D observes the entire row 30 of cell 28 at a given time, sensor assembly 60D can detect events occurring across the entire row 30.

[0050] For example, the combined transmitter / receiver 86 can sense changes in the reflected and received electromagnetic radiation 88. If detected during the filling of material 55 into RESS 24, this change in the received electromagnetic radiation 88 can indicate that material 55 has entered passage 58, and the sensor assembly 60D can trigger an alarm. Similarly, if the sensor assembly 60D detects a change in electromagnetic radiation 88 during operation of RESS 24, it can indicate the presence of gas 36 or debris entering passage 58 during thermal event 40 and trigger an alarm.

[0051] Figure 7 The illustration shows an example method 100 for assembling RESS 24. Method 100 begins at frame 102 by positioning the battery cell 28 near a cell support 44 for supporting the battery cell 28. The battery cell 28 is arranged relative to the cell support 44 such that the body of the cell support 44, which defines a row of holes 46, is in fluid communication with a corresponding cell vent 28B in one of the battery cells 28. The cell vent 28B is in fluid communication with a passage 58 through the holes 46 in the cell support 44.

[0052] The method then proceeds to block 104 and positions one of sensor assemblies 60A, 60B, 60C, or 60D within each of the thermal event paths 58. Each of the thermal event paths 58 extends parallel to a corresponding row of holes 46 in the unit support 44 to allow gas 36 to be released from RESS 24.

[0053] Method 100 then proceeds to frame 106, where the battery cell 28 is sealed within the RESS closure 32. In one example, the RESS closure 32 includes a tray 32-1 and a mating cap 32-2 and is configured to receive the battery cell 28, cell support 44, and sensor assemblies 60A, 60B, 60C, or 60D. Once the RESS closure 32 is complete, filling material can be added to the RESS 24 and allowed to expand and cure. During this installation process, sensor assemblies 60A, 60B, 60C, or 60D can detect the presence of filling material 55, as discussed in more detail above.

[0054] Detailed descriptions and accompanying drawings are provided to support and describe this disclosure, but the scope of this disclosure is defined only by the claims. While the best mode and some other embodiments for carrying out the claimed disclosure have been described in detail, various alternative designs and embodiments exist for practicing the disclosure as defined in the appended claims. Furthermore, features of the embodiments shown in the drawings or the various embodiments mentioned in this specification are not necessarily to be construed as independent embodiments. Rather, it is possible that each of the features described in one of the examples of embodiments may be combined with one or more other desired features from other embodiments to obtain other embodiments not described in words or by reference to the drawings. Therefore, such other embodiments fall within the framework of the appended claims.

Claims

1. A multi-cell rechargeable energy storage system (RESS), comprising: Multiple battery cells, wherein each battery cell includes a corresponding cell vent configured to exhaust gas; A unit support, the unit support being configured to support the plurality of battery units and having a support body having a plurality of holes arranged in a row, wherein each hole is configured to be aligned with and in fluid communication with a unit vent of one of the plurality of battery units; Multiple thermal event paths are located near the unit support, wherein each thermal event path extends parallel to a corresponding row of holes in the plurality of holes; Filling material, said filling material at least partially surrounding said plurality of battery cells; and A sensor assembly located in each of the plurality of thermal event pathways.

2. The multi-unit RESS according to claim 1, comprising an RESS closure having a tray and a mating cap, wherein, The RESS enclosure is configured to house the plurality of battery cells, cell supports, filling material, and sensor assemblies.

3. The multi-unit RESS according to claim 1, wherein, The sensor assembly includes a dielectric sensor assembly.

4. The multi-unit RESS according to claim 3, wherein, The dielectric sensor assembly extends the length of each corresponding row of holes in the plurality of holes.

5. The multi-unit RESS according to claim 1, wherein, The sensor assembly includes a plurality of sensors, wherein each of the plurality of sensors is aligned with a corresponding hole in the plurality of holes.

6. The multi-unit RESS according to claim 5, wherein, The plurality of sensors includes a plurality of capacitive sensors.

7. The multi-unit RESS according to claim 5, wherein, The plurality of sensors includes a plurality of temperature sensors.

8. The multi-unit RESS according to claim 1, wherein, The sensor assembly includes at least one transmitter and at least one receiver configured to receive signals from the at least one transmitter.

9. The multi-unit RESS according to claim 8, wherein, At least one transmitter is located near the first end of a corresponding one of the plurality of thermal event channels, and at least one receiver is located near the second end of a corresponding one of the plurality of thermal event channels.

10. The multi-unit RESS according to claim 9, wherein, The transmitter may be one of an infrared transmitter, an ultrasonic transmitter, or a laser beam transmitter.

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