Breather or vent cap assembly with integrated sensors for energy storage enclosures

Abstract

A breather assembly 100 comprising a housing 102 positioned within an enclosure of an energy storage system (Fig. 5, 1000); a permeable membrane 104 having a protective plastic or metal grill; a print

Description

TECHNICAL FIELD The present disclosure in general relates to energy storage systems and components. More particularly, it relates to breather or vent cap assemblies with integrated environmental sensors and associated system(s) for monitoring and managing internal conditions, including thermal runaway detection and venting control. BACKGROUND Battery monitoring within energy storage systems, particularly in Electric Vehicle, EV, or Hybrid Electric vehicle, HEV, applications is essential for ensuring safety, reliability, and extended battery life. However, existing monitoring techniques face significant limitations in effectively determining critical thermal events, such as thermal runaway. These limitations are due to inherent drawbacks of conventional sensors used in battery enclosures, impacting their sensitivity, response time, and overall efficacy in providing early warnings. Current temperature sensors installed within battery packs provide point measurements at specific locations, limiting their ability to detect spatial temperature variations or identify hotspots effectively. Additionally, temperature sensors generally have slower response times to rapid temperature changes, potentially missing critical events. These sensors also typically require physical contact with battery components, making installation complex and invasive, which adds to the development time. Similarly, pressure sensors used within battery enclosures have limited sensitivity to thermal changes, as they can only provide indirect indicators of thermal issues through pressure variations. Because of this, pressure sensors lack the precision needed for detailed thermal monitoring and early intervention. Furthermore, pressure sensors require regular calibration and maintenance to ensure reliable performance, posing additional operational burdens. The response time of pressure sensors is also insufficient for detecting gas concentration during thermal runaway events, which results in delayed activation of safety measures. These limitations in both temperature and pressure sensors reduce the reliability of conventional battery monitoring systems in providing early detection of thermal events, making it challenging to ensure the safety and longevity of battery systems. Thus, there is a need for an improved solution that integrates environmental and thermal monitoring capabilities within a single assembly, to offer comprehensive detection of thermal runaway events and environmental management within energy storage enclosures. SUMMARY Though breather or vent cap assemblies are widely known for venting and pressure management in energy storage systems, the existing solutions are not efficient in monitoring environmental conditions or providing early detection of thermal runaway events. Also, the existing solutions do not integrate real-time communication capabilities for enhanced monitoring and safety in energy storage systems. Therefore, there is a need for an improved breather or vent cap assembly that integrates monitoring capabilities, to provide real-time detection of thermal events, environmental condition tracking, and efficient communication with monitoring systems or external control units. It is therefore an object of the present disclosure to provide a breather or vent cap assembly with integrated monitoring for an energy storage system. The breather or vent cap assembly achieves efficient monitoring of environmental conditions and enables early detection of thermal runaway events to enhance safety and system reliability. Furthermore, it establishes seamless communication with external systems, to allow real-time alerts and effective management of critical conditions within energy storage systems. This and other objects are achieved by means of a breather or vent cap assembly, a system comprising the assembly, and a method for monitoring energy storage systems as defined in the appended claims. The term exemplary is in the present context to be understood as serving as an instance, example, or illustration. According to a first aspect of the present disclosure, a breather or vent cap assembly with integrated monitoring for an energy storage system is disclosed. The breather or vent cap assembly comprises a housing configured to be positioned within an enclosure of the energy storage system, a permeable membrane integrated within the housing, configured to allow controlled air exchange and prevent water ingress, wherein the membrane is protected from direct exposure to gases, battery dust, and flames by a grill or mesh structure made from plastic or metal, or a combination thereof. The breather or vent cap assembly further comprises a printed circuit board assembly, PCBA, housed within the housing, the PCBA comprising one or more sensors, or a combination of different sensor types, configured to monitor environmental conditions, detect thermal runaway, and provide early warning of thermal events within the energy storage system. Furthermore, the breather or vent cap assembly comprises a communication interface connected to the PCBA, the communication interface configured to transmit sensor data to a monitoring system for real-time monitoring. In addition, the one or more sensors, or a combination of different sensor types are integrated into the breather or vent cap to measure various environmental parameters, and provide both thermal runaway detection and venting support. Optionally, the one or more sensors, or a combination of different sensor types including temperature, pressure, gas concentration, humidity, and Laser Scattering, LSD, are protected by a top cover made from plastic or metal, or a combination thereof, and wherein the top cover includes passages to allow the sensors to accurately measure environmental parameters including temperature, pressure, gas concentration, humidity, and particulate matter. Optionally, the venting support includes activities related to air exchange control, moisture regulation, and humidity control. Optionally, the permeable membrane is configured as a single stage or a dual stage membrane, and wherein: in the single stage configuration, the membrane ruptures at a predetermined pressure threshold, to release additional gas, and in the dual stage configuration, the membrane does not rupture, but releases additional gas by activating a movable cover assembly, the activation is provided by a spring and a movable diaphragm made of a soft material. Optionally, the one or more sensors, or a combination of different sensor types are positioned either at the center, to the left side, or at any part of the housing, and are configured to individually sense any of the parameters required for monitoring environmental conditions and detecting thermal runaway within the energy storage system. Optionally, the communication interface enables the breather or vent cap assembly to communicate with external electronic control units, ECUs, including a battery management system or airbag control unit, to alert occupants about hazardous or thermal runaway events. Optionally, the breather or vent cap assembly is configured to directly communicate with occupants via sound, light, or other alerting mechanisms to notify them of hazardous or thermal runaway events. Optionally, the communication interface is configured to transmit sensor data to the monitoring system via a wired or wireless communication link for real-time monitoring, and wherein the communication is fulfilled via analog or digital communication means. Optionally, the one or more sensors, or a combination of different sensor types detect gases including hydrogen, H2, nitrogen, N2, carbon monoxide, CO, carbon dioxide, CO2, hydrocarbons, HC, and volatile organic compounds, VOCs. Optionally, the breather or vent cap assembly is configured to be of any shape, including square, rectangular, circular, or other geometric configurations, is mountable within the enclosure of the energy storage system using a fastener or press fit mechanism, and is configured to achieve an ingress protection, IP, rating selected from IP64, IP65, IP67, IP68, or IP69, depending on the specific application requirements. Optionally, the housing is constructed from one or more materials including plastic, metal, or a combination thereof, and wherein the housing includes a sealing ring positioned to secure the housing to a mating part of the energy storage system, the sealing ring configured to provide environmental isolation and structural stability. Optionally, the breather or vent cap assembly is powered by the battery of the energy storage system to which it is attached to. According to another aspect of the present disclosure, the system monitoring an energy storage system is disclosed. The system comprises a breather or vent cap assembly with integrated monitoring for an energy storage system. The breather or vent cap assembly comprises a housing configured to be positioned within an enclosure of the energy storage system, a permeable membrane integrated within the housing, configured to allow controlled air exchange and prevent water ingress, wherein the membrane is protected from direct exposure to gases, battery dust, and flames by a grill or mesh structure made from plastic or metal, or a combination thereof. The breather or vent cap assembly further comprises a printed circuit board assembly, PCBA, housed within the housing, the PCBA comprising one or more sensors, or a combination of different sensor types, configured to monitor environmental conditions, detect thermal runaway, and provide early warning of thermal events within the energy storage system. Furthermore, the breather or vent cap assembly comprises a communication interface connected to the PCBA, the communication interface configured to transmit sensor data to a monitoring system for real-time monitoring. In addition, the one or more sensors, or a combination of different sensor types are integrated into the breather or vent cap to measure various environmental parameters, and provide both thermal runaway detection and venting support. The system further comprises a processor communicatively connected to the PCBA, configured to: receive sensor data from the breather or vent cap assembly comprising one or more sensors, or a combination of different sensor types configured to monitor environmental parameters, execute algorithms to analyze the sensor data for detecting thermal runaway conditions and predicting maintenance requirements based on environmental parameters, and generate alerts or control signals based on the analysis. According to another aspect of the present disclosure, there is provided a computer program when loaded and run on a system, causes a processing circuitry to perform a method for monitoring an energy storage system, wherein the method comprises: receiving sensor data from a breather or vent cap assembly comprising one or more sensors, or a combination of different sensor types configured to monitor environmental parameters, analyzing the sensor data to detect thermal runaway conditions and predict maintenance needs based on the monitored environmental parameters, and generating alerts or control signals based on the analysis. According to another aspect of the present disclosure, there is provided a computer-readable medium having stored thereon a computer program. Some embodiments disclosed herein have one or more of the following advantages: - The proposed breather or vent cap assembly enables precise monitoring of environmental conditions within the energy storage system, enhancing early detection and prevention of hazardous events such as thermal runaway. - The integration of multiple sensors in the assembly allows real-time detection of critical parameters such as temperature, pressure, humidity, and gas concentrations, to ensure robust safety mechanisms. - The proposed breather or vent cap assembly provides seamless communication with external monitoring systems, such as battery management systems, to provide alerts and maintain operational stability. - Compared with available solutions, the proposed assembly optimizes the balance between effective venting support and reliable environmental monitoring, ensuring both system protection and efficiency. - The assembly is adaptable to diverse configurations and is easily incorporated into various energy storage systems while maintaining high ingress protection standards and structural integrity. Other advantages may be readily apparent to one having skill in the art. Certain embodiments may have none, some, or all of the recited advantages. BRIEF DESCRIPTION OF THE DRAWINGS The foregoing will be apparent from the following more particular description of the example embodiments, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the example embodiments. FIG. 1 is an exploded view of the breather or vent cap assembly, illustrating the housing, the permeable membrane, printed circuit board assembly, PCBA, one or more sensors, and other components; FIG. 2 is a sectional diagram of the permeable membrane, demonstrating its functionality in allowing air flow while blocking moisture ingress; FIG. 3 is a sectional diagram of top cover, showing slots for exposing sensors; FIG. 4 is a detailed view of different possible sensor placements within the housing; FIG. 5 illustrates an exemplary scenario of specific sensor detections and the generation of real-time alerts, according to some embodiments; FIG. 6 is a sectional diagram of multiple possible configurations of the breather or vent cap assembly, accommodating various design and operational needs; FIG. 7 illustrates the breather or vent cap assembly integrated within an energy storage system, depicting its placement and connectivity; FIG. 8 illustrates a flow chart for a method for monitoring an energy storage system using the breather or vent cap assembly, according to some embodiments; FIG. 9 discloses an example computing environment according to some embodiments. DETAILED DESCRIPTION Aspects of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings. The systems and methods disclosed herein can, however, be realized in many different forms and should not be construed as being limited to the aspects set forth herein. Like numbers in the drawings refer to like elements throughout. The terminology used herein is for the purpose of describing particular aspects of the disclosure only and is not intended to limit the invention. It should be emphasized that the term “comprises / comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components, but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. Embodiments of the present disclosure will be described and exemplified more fully hereinafter with reference to the accompanying drawings. The solutions disclosed herein can, however, be realized in many different forms and should not be construed as being limited to the embodiments set forth herein. It will be appreciated that when the present disclosure is described in terms of a system and a method, it may also be embodied in one or more processors and one or more memories coupled to the one or more processors, wherein the one or more memories store one or more programs that perform the steps, services and functions disclosed herein when executed by the one or more processors. FIG. 1 illustrates an exploded view of a breather or vent cap assembly 100 for an energy storage system 1000 (shown in Fig. 7), highlighting its various components and their spatial arrangement. The breather or vent cap assembly 100 is configured to provide dual functionalities of vacuum prevention and pressure release, while enabling environmental monitoring and thermal runaway detection in the energy storage system 1000. This design provides safety and operational stability by controlling air exchange and preventing ingress of moisture and contaminants. In addition, the breather or vent cap assembly 100 addresses challenges posed by fluctuating internal pressures and external environment conditions, to ensure reliable performance over prolonged operational cycles. The first aspect of this disclosure describes the breather or vent cap assembly 100 for monitoring environmental parameters and supporting venting operations in an energy storage system, comprising: a housing 102 configured to be positioned within the enclosure of the energy storage system, a permeable membrane 104 integrated into the housing to allow controlled air exchange while preventing water ingress, where the membrane is protected from direct contact with gases, battery dust, and flames by a grill or mesh structure made from plastic or metal, or a combination thereof. The assembly further comprises a printed circuit board assembly, PCBA, 106 housed within the housing, comprising one or more sensors 108 or a combination of different sensor types, configured to monitor environmental conditions, detect thermal runaway, and provide early warnings of thermal events. Furthermore, the assembly comprises a communication interface 110 connected to the PCBA 106, configured to transmit sensor data to a monitoring system for real-time monitoring. The one or more sensors 108 or a combination of different sensor types are integrated into the breather or vent cap to measure various environmental parameters, and provide both thermal runaway detection and venting support. The housing 102 encases and protects other components of the breather or vent cap assembly 100. The housing 102 comprises panels 102a, 102b, 102c and 102d, each serving a distinct function to ensure the performance and reliability of the assembly. 102a includes top cover 300 and a protective grill or mesh. This panel provides structural integrity to the overall assembly, by providing both mechanical support and protection for components inside the assembly. The protective grill or mesh safeguards the permeable membrane 104 from direct exposure to potentially damaging elements such as battery gases, dust, and flames. Additionally, this panel facilitates air exchange and moisture ingress, enabling proper environmental regulation within the energy storage system. 102b is dedicated to frame fitting and includes a sealing ring 114 around its perimeter. The sealing ring 114 allows an airtight fit when the panels are assembled and the assembly is mated to the energy storage system 1000, to maintain the integrity of the housing and preventing unwanted leakage. The sealing ring 114 ensures that the housing maintains its integrity, even under fluctuating internal pressures or external environmental conditions. 102c houses the permeable membrane 104 and secures other panels together. It integrates the permeable membrane 104 within the assembly, to ensure that it is properly sealed and securely held in place. The permeable membrane 104 allows controlled air exchange while preventing the ingress of moisture or contaminants. In addition, panel 102c includes another sealing ring 114 that mates with the energy storage system, providing an airtight seal to prevent any unwanted leakage. 102d is snap-fit vent panel to enable air exchange and moisture ingress. This panel allows for passive ventilation, to help manage humidity and internal air pressure. The snap-fit panel allows for easy assembly and secure fitting, ensuring that the venting mechanism remains functional throughout the operational life of the energy storage system. The panels 102a, 102b, 102c, and 102d are interconnected using hot rivets or bolts, which provide strong mechanical fastening and ensure that the housing remains robust under operational stresses. The permeable membrane 104 is positioned within the housing 102, configured to allow air to flow bidirectionally, to maintain the pressure balance while preventing the ingress of moisture or fine particulates. The PCBA 106 is positioned below or adjacent to the permeable membrane 104 to integrate one or more sensors, or a combination of different sensor types including sensors 108a-108n (collectively referred to as ‘sensors 108’), including temperature sensors, humidity sensors, gas detectors, and laser scattering detection, LSD, sensors, to monitor environmental parameters including temperature, pressure, gas concentration, humidity, and particulate matter. The PCBA 106 is securely fixed within the housing 102 using connection mechanisms such as snap-fit joints, pins, screws, or hot rivets, to ensure durability and ease of assembly. The permeable membrane 104 has a grill or mesh structure made from plastic or metal to avoid direct contact with gases, battery dust, and flames. The protective grill or mesh ensures durability against high-pressure surges or external mechanical impacts, to further enhance the longevity of the breather or vent cap assembly 100 under extreme conditions. The positioning of the sensors 108 below the permeable membrane 104 ensures that the sensors 108 remain shielded from direct exposure to vented gases or debris, thereby enhancing their operational reliability. This arrangement also minimizes the impact of external contaminants or sensor readings, ensuring consistent and accurate environmental monitoring. In an example, the housing 102 is designed to provide environmental isolation and structural stability, supported by a sealing ring 114 that ensures tight integration with a mating part of the energy storage system 1000. The sealing ring 114 is positioned at the interface between the housing 102 and the energy storage system 1000 to provide tight coupling. This ensures durability and reliable operation under harsh conditions. The sealing ring 114 is fabricated from high-grade elastomers to provide both chemical resistance and flexibility, allowing it to maintain a secure seal even under thermal expansion or contraction. In another example, the communication interface 110 is configured to support both wired and wireless protocols including CAN, Zigbee, Bluetooth, Wi-Fi, or proprietary communication standards, to enable seamless integration with diverse energy storage system configurations. In an embodiment, the one or more sensors 108, or a combination of different sensor types including temperature, pressure, gas concentration, humidity, and Laser Scattering, LSD, are protected by a top cover 300 made from plastic or metal, or a combination thereof, and wherein the top cover 300 includes passages to allow the sensors to accurately measure environmental parameters including temperature, pressure, gas concentration, humidity, and particulate matter. In an embodiment, the venting support includes activities related to air exchange control, moisture regulation, and humidity control. In a preferred embodiment, the breather or vent cap assembly 100 is mounted on the top enclosure of an energy storage system 1000. The permeable membrane 104 regulates internal pressure, while the PCBA 106 continuously monitors various environmental parameters including temperature, pressure, gas concentration, humidity, and particulate matter. The top-mounted configuration allows for efficient venting of gases and easy access for maintenance or replacement, ensuring minimal disruption to system operation. When abnormal environmental parameters are detected, the PCBA 106 sends an alert to a central monitoring system 502 as described in Fig. 5 via the communication interface 110. The central monitoring system 502 as described in Fig. 5 then initiates pre-emptive safety measures including controlled venting or total system shutdown, to prevent catastrophic failures. Fig. 2 illustrates a sectional diagram of the permeable membrane 104, according to some embodiments herein. The permeable membrane 104 comprises a multi-layer structure provide controlled air exchange while preventing ingress of moisture and contaminants. The multi-layer configuration is independent of its functional configuration as a single-stage or dual-stage membrane. These layers work in conjunction to provide moisture repellence, particulate filtration, and structural integrity. This multi-layer configuration therefore enhances the robustness of the membrane, making it suitable for use in diverse environmental and operational conditions. The upper layer 202 of the permeable membrane 104 includes a hydrophobic material to repel moisture, while the lower layer 204 is used for fine particulate filtration. The hydrophobic upper layer 202 is chemically treated to achieve superior water repellence, to ensure that the integrity of the lower filtration layer 204 remains unaffected by condensation or liquid exposure. The permeable membrane 104 operates by enabling differential pressure regulation within the energy storage system 1000, to maintain stability across varying environmental parameters. This differential pressure mechanism avoids stress build-up within the enclosure, thereby extending the operational lifespan of the energy storage system 1000. In an example, the permeable membrane 104 includes an intermediate layer 206 between the hydrophobic upper layer 202 and the particulate filtration lower layer 204. This intermediate layer provides additional functionality, such as enhanced structural support, flame retardance, or adsorption of harmful chemical vapors. In an embodiment, the permeable membrane 104 is shielded by a grill or mesh structure, which may be made of plastic, metal, or a combination thereof, to safeguard against direct contact with corrosive gases, battery dust, and flames. In an example, the grill or mesh structure may have optimized pore size and material thickness to balance protection with air exchange efficiency. For example, a stainless stell mesh may be used in high temperature environments, while a polymer-based mesh may be selected for lightweight applications. In an embodiment, the permeable membrane 104 is configured as a single stage or a dual stage membrane, and wherein: - in the single stage configuration, the membrane ruptures at a predetermined pressure threshold, to release additional gas, and - in the dual stage configuration, the membrane does not rupture but releases additional gas by activating a movable cover assembly, the activation is provided by a spring and a movable diaphragm made of a soft material. In an example, the permeable membrane 104 is configured as a single stage membrane that ruptures at a predefined pressure to release gas, the predefined pressure threshold may be customized based on the energy storage system’s design and safety requirements, to ensure compatibility with a wide range of applications. In another example, the permeable membrane 104 is configured as a dual stage membrane that works with a movable cover, spring, and movable diaphragm to release gas without rupturing. In this configuration, the movable cover acts as a mechanical safeguard, while the spring regulates the force required for activation. The movable diaphragm ensures consistent performance by maintaining a sealed environment during normal operation. In some examples, the permeable membrane 104 is configured to adapt to meet requirements of various operating environments including high pressure and harsh conditions using reinforced layers including high strength polymers, woven composites, or metallic mesh integrated with hydrophobic materials. The reinforced layers provide not only increased durability but also resistance to chemical degradation, making the permeable membrane 104 suitable for energy storage systems in extreme environmental settings. Furthermore, the permeable membrane 104 may have adaptability that extends to its dimensional customization, to allow it to be seamlessly integrated into enclosures of varying sizes and geometries. Fig. 3 illustrates a sectional diagram of the top cover 300 surrounding the PCBA 106 of the breather and vent cap assembly 100, according to some embodiments herein. The top cover 300 includes slots 302a-302n (collectively referred to as ‘slots 302’) to expose the integrated one or more sensors, or a combination of different sensor types on the PCBA 106 to environmental parameters. The slots 302 are positioned to detect various environmental parameters including temperature, pressure, gas concentration, humidity, and particulate matter efficiently while protecting the sensors from external physical damage. The top cover 300 is made from plastic or metal, or a combination thereof, chosen to provide structural durability and resistance to environmental wear. The top cover 300 is further configured to enable optimized airflow towards the sensors 108 to ensure precise and real-time data collection. This optimization is achieved by angling or shaping the slots 302 to direct airflow strategically while minimizing turbulence that could interfere with sensor readings. In an example, the slots 302 may be coated with an anti-corrosive layer to withstand exposure to harsh gases or moisture over prolonged usage. In another example, the slots 302 may vary in size depending on sensitivity requirements of the sensors 108. For instance, smaller slots are used for particulate matter sensors to facilitate higher air exchange rates. In some examples, the positioning of the slots 302 is adapted to align with specific sensor arrays on the PCBA 106, ensuring accurate detection and minimal signal interference. In a preferred embodiment, the top cover 300 includes an integrated sealing mechanism such as a gasket or adhesive lining, at its edges to form a protective enclosure around the PCBA 106. This ensures environmental isolation and prevents contaminants from entering through unintended gaps, thereby prolonging the operational life of the sensors 108. The top cover 300 is secured to the housing either through plastic soldering, which provides a permanent seal, hot rivets, or by using bolts, which allows for easier disassembly and maintenance. The integrated sealing mechanism works in conjunction with the securing mechanism to provide a robust and protective enclosure around the PCBA 106. Fig. 4 illustrates a detailed view 400 of various sensor placements within the housing 102 of the breather or vent cap assembly 100, according to some embodiments herein. The PCBA 106 may include a temperature sensor 402, a humidity sensor 404, and a gas detector 406. These sensors are arranged to detect parameters critical to identifying potential thermal runaway conditions or other hazards within the energy storage system 1000. The placement of each sensor is carefully optimized to ensure maximum coverage of critical areas while maintaining minimal interference from other components in the assembly. In an embodiment, the one or more sensors 108, or a combination of different sensor types are positioned either at the center, to the left side, or at any part of the housing 102, and are configured to individually sense any of the parameters required for monitoring environmental conditions and detecting thermal runaway within the energy storage system In an example, the temperature sensor 402 detects localized overheating, while the gas detector 406 identifies chemical off-gassing indicative of thermal runaway. The temperature sensor 402 is configured to provide rapid response to thermal anomalies, using its high sensitivity to detect even minor deviations in operating temperature. Additionally, an environmental sensor 408 may be included to measure external conditions such as ambient pressure and humidity, ensuring the energy storage system’s operation is adapted to environmental factors. In another example, the temperature sensor 402 is strategically placed to detect localized overheating within the energy storage system 1000. The temperature sensor 402 is configured to identify hotspots that may signal imminent thermal runaway or compromised battery performance. In another example, multiple temperature sensors 402 are distributed across the PCBA 106 to generate a comprehensive thermal profile, enabling predictive maintenance and early anomaly detection. The distributed arrangement enhances the detection of thermal gradients across the energy storage system 1000. In another example, the humidity sensor 404 measures internal moisture levels within the energy storage system 1000. The humidity sensor 404 is calibrated to detect minor increases in humidity, which may result from condensation or breaches in sealing mechanism of the energy storage system 1000. Rapid identification of moisture ingress ensures timely intervention to prevent degradation of battery performance. In another example, the gas detector 406 identifies chemical off gassing, such as release of volatile organic compounds, VOCs, or hydrogen indicative of cell venting or thermal runaway. The gas detector 406 may employ advanced detection principles such as infrared absorption or electrochemical sensing, to ensure accurate identification of hazardous emissions under varying environmental conditions. In another example, the PCBA 106 may include laser scattering detection, LSD, sensor to detect fine particulate emissions resulting from breakdown of battery components. This sensor enables precise quantification of particulates, providing valuable data for assessing battery health. In another example, the gas detector 406 may operate on multiple detection principles such as infrared absorption or electrochemical sensing, to enhance accuracy. In another example, the sensors 108 may be arranged to optimize coverage of critical areas within the housing 102 while minimizing interference from neighboring components. In addition, the PCBA 106 may incorporate shielding layers to reduce electromagnetic interference, to ensure that the sensor readings remain consistent and accurate. In some examples, the PCBA 106 may include an integrated calibration circuit to harmonize readings from multiple sensors, to ensure accuracy over time. This calibration circuit may account for environmental drift and sensor wearing, to maintain long term reliability and reduce the need for frequent manual recalibration. In a preferred embodiment, the temperature sensor 402 is positioned near battery terminals to detect localized overheating, while the gas detector 406 maybe used to detect chemical emissions in the airflow rapidly. The humidity sensor 404 monitors internal moisture levels, which may increase during adverse weather conditions. The environmental sensor 408 captures environmental parameters such as atmospheric pressure changes. This sensor configuration ensures comprehensive monitoring of internal and external parameters critical to the safe and efficient operation of the energy storage system 1000. Fig. 5 illustrates an exemplary scenario 500 of sensor detection and alert generation, according to some embodiments herein. The breather and vent cap assembly 100, through its PCBA 106, detects changes in environmental conditions including elevated temperature, gas leakage, or excessive humidity. These parameters are critical indicators of potential hazards such as thermal runaway, structural degradation, or environmental contamination within the energy storage system 1000. Upon detecting such parameters, the sensors 108 transmit signals to a central monitoring system 502. The central monitoring system 502 may include external electronic control units, ECUs, including a battery management system or airbag control unit. The communication interface 110 in the PCBA 106 enables real-time transmission of sensor data to the central monitoring system 502 via secure and robust communication protocols such as Zigbee, Bluetooth low energy, BLE, or Wi-Fi. The protocol selection may depend on the application requirements, to ensure reliable connectivity under varying conditions. The central monitoring system 502 generates real-time alerts to notify operators and occupants of potential hazards. In an embodiment, the communication interface 110 enables the breather or vent cap assembly 100 to communicate with external electronic control units, ECUs, including a battery management system or airbag control unit, to alert occupants about hazardous or thermal runaway events. In an embodiment, the breather or vent cap assembly 100 is configured to directly communicate with occupants via sound, light, or other alerting mechanisms to notify them of hazardous or thermal runaway events. For example, the alerts may be presented in various formats such as visual indicators on dashboards, audible alarms, or mobile notifications, to ensure prompt awareness and action. In an embodiment, the breather or vent cap assembly 100 is powered by the battery of the energy storage system to which it is attached to. In an embodiment, the communication interface 110 is configured to transmit sensor data to the monitoring system via a wired or wireless communication link for real-time monitoring, and wherein the communication is fulfilled via analog or digital communication means. In an embodiment, the one or more sensors 108, or a combination of different sensor types detect gases including hydrogen, H2, nitrogen, N2, carbon monoxide, CO, carbon dioxide, CO2, hydrocarbons, HC, and volatile organic compounds, VOCs. In an example, the central monitoring system 502 incorporates an artificial intelligence, Al, or machine learning, ML, algorithm to analyze sensor data. This predictive analytics capability enables to identify early warning signs and patterns that may precede catastrophic events, to allow preemptive safety measures. These alerts may trigger automated safety mechanisms, such as system shutdown or controlled venting, to ensure proactive mitigation of risks. The venting mechanism may work in conjunction with the breather or vent cap assembly 100 in a controlled manner, using the permeable membrane 104 to safely release pressure while preventing external contaminants from entering the system. Also, system shutdowns may be executed in a phased manner to avoid abrupt power loss, thereby ensuring the safety of connected systems. In an example, the central monitoring system 502 may also communicate with external systems such as battery management system, BMS, or engine control module, ECM, to coordinate a broader safety response. For instance, in the event of a detected thermal runaway, the central monitoring system 502 may activate localized cooling mechanisms, activate fire suppression systems, and inform the occupants or nearby personnel. In an example, elevated temperature detected by the temperature sensor 402 near the battery terminals may trigger an immediate alert. Simultaneously, the gas detector 406 may identify chemical off-gassing, such as VOCs or hydrogen, indicative of cell venting or thermal degradation. The combination of these parameters allows the central monitoring system 502 to assess the severity of the event and prioritize the corresponding safety action, such as selective venting or initiating thermal isolation. In addition, the central monitoring system 502 may log data for post-incident analysis and predictive maintenance. This data may include time-stamped records of temperature spikes, gas concentrations, or moisture levels, to provide valuable insights for diagnosing root causes and improving the predictive analytics for generating realtime alerts and / or triggering automated safety mechanisms. Fig. 6 illustrates a sectional diagram 600 of multiple possible configurations of the breather and vent cap assembly 100 within an energy storage system 1000, according to some embodiments herein. These configurations highlight the adaptability of breather or vent cap assembly 100 to various operational or design constraints of the energy storage system 1000. Various configurations include alternative placements of the permeable membrane 104, sensor arrangements, and shapes of the housing 102 to adapt to specific energy storage systems. In an embodiment, the breather or vent cap assembly 100 is configured to be of any shape, including square, rectangular, circular, or other geometric configurations, is mountable within the enclosure of the energy storage system using a fastener or press fit mechanism, and is configured to achieve an ingress protection, IP, rating within the range of IP64 to IP69 or any other suitable standard that provides comparable protection against ingress of dust and water, depending on the specific application requirements. In an embodiment, the housing 102 is constructed from one or more materials including plastic, metal, or a combination thereof, and wherein the housing 102 includes a sealing ring positioned to secure the housing to a mating part of the energy storage system 1000, the sealing ring configured to provide environmental isolation and structural stability. In an example, the placement of the permeable membrane 104 is optimized to align with primary airflow within the energy storage system 1000, to ensure efficient pressure regulation and contaminant filtration. The permeable membrane 104 may be positioned vertically, horizontally, or at an inclined angle within the housing 102, depending on the space constraints and airflow dynamics of the system. In another example, the breather or vent cap assembly 100 is configured to be of any shape, including square, rectangular, circular, or other geometric configurations, is mountable within the enclosure of the energy storage system using a fastener, press fit mechanism, or adhesive bonding. The shape and mounting methods may be adapted to enhance compatibility with diverse energy storage systems, ranging from compact battery packs to large-scale energy storage units. In another example, in a high-pressure configuration, a reinforced housing 602 and an enhanced membrane 604 are used to withstand extreme operational conditions. The reinforced housing 602 may incorporate high strength materials such as polycarbonate composites or stainless steel, designed to endure shocks, vibration, and prolonged exposure to high temperatures. The enhanced membrane 604 may include multi-layer construction with additional reinforcement layers such as aramid fibers or metallic meshes, to prevent rupture or sudden pressure spikes. In another example, additional sensors 608 are included in specialized configurations for advanced monitoring. These additional sensors 608 may include vibration sensors to detect mechanical instabilities, acoustic sensors to monitor abnormal sound patterns indicative of anomalies, or proximity sensors to detect unexpected changes in component alignment within the energy storage system 1000. In a preferred embodiment, the housing 102 is designed with modular compartments to accommodate interchangeable sensor modules, to allow customization based on specific application requirements. For example, a modular compartment may house a high sensitivity gas detector in applications where chemical off gassing is a primary concern, while another module may integrate environmental sensors for energy storage units. In addition, the configuration may incorporate thermal isolation barriers within the housing to shield sensitive components from heat sources, to enhance the durability and performance of the breather or vent cap assembly 100. In some examples, the breather or vent cap assembly 100 may also include integrated routing channels to guide airflow over specific sensors, to ensure accurate detection and minimize sensor interference from turbulent flows. Fig. 7 illustrates the integration of a monitoring system for an energy storage system 1000, wherein the monitoring system includes the breather or vent cap assembly 100 and a processor 702 configured to process sensor data for advanced system monitoring and predictive maintenance. In one aspect, a system 700 for monitoring an energy storage system is disclosed. The system comprising the breather or vent cap assembly described in Fig. 1, a processor 702 communicatively connected to the PCBA 106, configured to: receive sensor data from the breather or vent cap assembly 100, execute algorithms to analyze the sensor data for detecting thermal runaway conditions and predicting maintenance requirements based on the analysis, and generate alerts or control signals based on the analysis. The breather or vent cap assembly 100, as described in preceding embodiments, includes a PCBA 106 with integrated sensors 108 for detecting critical environmental parameters such as temperature, pressure, humidity, gas concentration, and particulate matter. The sensors 108 transmit this data to the processor 702 through a communication interface 110. The communication interface 110 may be either wired or wireless supporting protocols such as CAN bus, BLE, or ZigBee, to support reliable and real-time data transfer. The processor 702 is configured to execute algorithms that analyse the incoming sensor data to detect potential hazards such as thermal runaway conditions, or deviations in environmental parameters that may indicate the need for maintenance. These algorithms may include artificial intelligence, Al, or machine learning, ML, models or rule-based models, to enable the processor 702 to identify patterns or anomalies in the sensor data. In an example, the processor 702 identifies a rapid temperature increase near battery terminals, detected by a temperature sensor, as a precursor to thermal runaway. The processor 702 generates an alert and may trigger safety measures, such as controlled venting or system shutdown, to prevent catastrophic failure. In addition, the processor 702 may monitor trends in humidity levels or gas concentration to predict maintenance requirements, such as the need for replacing filters or addressing gas leaks. The system also includes an alert generation module 704, communicatively connected to the processor 702, and configured to send alerts in various formats, such as visual indicators, audible alarms, or notifications to remote monitoring platforms. These alerts enable occupants to take timely action or automate safety responses, minimizing risks associated with adverse thermal conditions. Fig. 8 illustrates a flow chart 800 for a method of monitoring an energy storage system using the breather or vent cap assembly 100, according to some embodiments herein. At step 802, the method 800 receives sensor data from the breather or vent cap assembly 100. Specifically, the sensors 108 on the PCBA 106 monitor environmental parameters such as temperature, pressure, humidity, gas concentration, and particulate matter. The sensor data is transmitted to a processor 702 through a secure and reliable communication interface 110. At step 804a, the method 800 analyzes the sensor data for detecting thermal runaway conditions. Specifically, the processor 702 employs advanced computational techniques, including rule-based logic and machine learning models, to identify anomalies or rapid changes in sensor readings. For example, a sudden increase in temperature near battery terminals, detected by the temperature sensor 402, may indicate the onset of thermal runaway. The algorithm cross-references other parameters, such as gas concentration from the gas detector 406, to confirm the hazard. At step 804b, the method 800 predicts maintenance requirements based on the analysis. Specifically, the processor 702 monitors trends and deviations in environmental parameters to identify potential maintenance needs. For example, persistent increases in humidity levels detected by the humidity sensor 404 may signal the need to replace the permeable membrane 104 or address sealing issues within the housing 102. Similarly, trends in gas concentration can indicate aging or deterioration of battery cells, prompting preemptive maintenance. At step 806, the method 800 generates alerts or control signals based on the analysis. Specifically, the processor 702 communicates the alerts to occupants via visual, audible, or digital notifications. Alerts may also be sent to a central monitoring system 502 or a connected cloud platform for remote monitoring. In addition, the method 800 may trigger automated control signals to activate safety mechanisms, such as: - initiating controlled venting through the breather or vent cap assembly 100 to release excessive pressure. - executing a system-wide shutdown to prevent further escalation of hazardous conditions. FIG. 9 illustrates an example-computing environment 900 implementing the breather or vent cap assembly 100 for an energy storage system 1000, the method 800 for monitoring the energy storage system 1000 as shown in FIG.s 1 to 8 for environmental monitoring and thermal runaway detection in the energy storage system 1000. The example-computing environment 900 further implementing the system 800, the method 800 for monitoring the energy storage system 1000 as shown in FIG.s 1 to 8 for environmental monitoring and thermal runaway detection in the energy storage system 1000. As depicted in FIG. 9, the computing environment 900 comprises at least one data processing unit 906 that is equipped with a control unit 902 and an arithmetic logic unit, ALU, 904, a plurality of networking devices 908 (for example device facilitating BLE localization under BLE protocol of communication) and a plurality Input output, I / O devices 910, a memory 912, a storage 914. The data processing unit 906 may be responsible for implementing the system 1000 and method 800 described in FIG. 8. For example, the data processing unit 906 in some embodiments be equivalent to the processing circuitry of the assembly described above in conjunction with FIG. 7. For another example, the data processing unit 906 in some embodiments be equivalent to the processing circuitry of the assembly described above in conjunction with FIG. 7. The data processing unit 906 is capable of executing software instructions stored in memory 912. The data processing unit 906 receives commands from the control unit 902 in order to perform its processing. Further, any logical and arithmetic operations involved in the execution of the instructions are computed with the help of the ALU 904. The computer program is loadable into the data processing unit 906, which may, for example, be comprised in an electronic apparatus. When loaded into the data processing unit 906, the computer program may be stored in the memory 912 associated with or comprised in the data processing unit 906. According to some embodiments, the computer program may, when loaded into and run by the data processing unit 906, cause execution of method steps according to, for example, the methods illustrated in FIG. 8 described herein. The overall computing environment 900 may be composed of multiple homogeneous and / or heterogeneous cores, multiple CPUs of different kinds, special media and other accelerators. Further, the plurality of data processing unit 906 may be located on a single chip or over multiple chips. The algorithm comprising of instructions and codes required for the implementation are stored in either the memory 912 or the storage 914 or both. At the time of execution, the instructions may be fetched from the corresponding memory 912 and / or storage 914, and executed by the data processing unit 906. In case of any hardware implementations various networking devices 908 or external I / O devices 910 may be connected to the computing environment to support the implementation through the networking devices 908 and the I / O devices 910. The embodiments disclosed herein can be implemented through at least one software program running on at least one hardware device and performing network management functions to control the elements. The elements shown in FIG. 9 include blocks which can be at least one of a hardware device, or a combination of hardware device and software module. Reference signs • Energy storage system 1000 • Breather or vent cap assembly 100 • Housing 102 • Permeable membrane 104 • Printed circuit board assembly, PCBA, 106 • One or more sensors, or a combination of different sensor types 108 • Communication interface 110 • Sealing ring 114 • Upper layer 202 • Lower layer 204 • Intermediate layer 206 • Top cover 300 • Slots 302 • Temperature sensor 402 • Humidity sensor 404 • Gas detector 406 • Environmental sensor 408 • Central monitoring system 502 • Reinforced housing 602 • Enhanced membrane 604 • Additional sensors 608 • Processor 702 • Alert generation module 704

Claims

1. A breather or vent cap assembly (100) with integrated monitoring for an energy storage system (1000), characterisedinthat, the breather or vent cap assembly (100) comprising:a housing (102) configured to be positioned within an enclosure of the energy storage system;a permeable membrane (104) integrated within the housing, configured to allow controlled air exchange and prevent water ingress, wherein the membrane (104) is protected from direct exposure to gases, battery dust, and flames by a grill or mesh structure made from plastic or metal, or a combination thereof;a printed circuit board assembly, PCBA, (106) housed within the housing (102), the PCBA (106) comprising one or more sensors (108), or a combination of different sensor types, configured to monitor environmental conditions, detect thermal runaway, and provide early warning of thermal events within the energy storage system (1000);a communication interface (110) connected to the PCBA (106), the communication interface (110) configured to transmit sensor data to a monitoring system for real-time monitoring;wherein the one or more sensors (108), or a combination of different sensor types are integrated into the breather or vent cap (100) to measure various environmental parameters, and provide both thermal runaway detection and venting support.

2. The breather or vent cap assembly (100) according to claim 1, wherein the one or more sensors (108), or a combination of different sensor types including temperature, pressure, gas concentration, humidity, and Laser Scattering, LSD, are protected by a top cover (300) made from plastic or metal, or a combination thereof, and wherein the top cover (300) includes passages to allow the sensors (108) to accurately measure environmental parameters including temperature, pressure, gas concentration, humidity, and particulate matter.

3. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the venting support includes activities related to air exchange control, moisture regulation, and humidity control.

4. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the permeable membrane (104) is configured as a single stage or a dual stage membrane, and wherein:in the single stage configuration, the membrane ruptures at a predetermined pressure threshold, to release additional gas; andin the dual stage configuration, the membrane does not rupture, but releases additional gas by activating a movable cover assembly, the activation is provided by a spring and a movable diaphragm made of a soft material.

5. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the one or more sensors (108), or a combination of different sensor types are positioned either at the center, to the left side, or at any part of the housing (102), and are configured to individually sense any of the parameters required for monitoring environmental conditions and detecting thermal runaway within the energy storage system (1000).

6. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the communication interface (110) enables the breather or vent cap assembly (100) to communicate with external electronic control units, ECUs, including a battery management system or airbag control unit, to alert occupants about hazardous or thermal runaway events.

7. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the breather or vent cap assembly (100) is configured to directly communicate with occupants via sound, light, or other alerting mechanisms to notify them of hazardous or thermal runaway events.

8. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the communication interface (110) is configured to transmit sensor data to the monitoring system via a wired or wireless communication link for real-time monitoring, and wherein the communication is fulfilled via analog or digital communication means.

9. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the one or more sensors (108), or a combination of different sensor types detect gases including hydrogen, H2, nitrogen, N2, carbon monoxide, CO, carbon dioxide, CO2, hydrocarbons, HC, and volatile organic compounds, VOCs.

10. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the breather or vent cap assembly (100) is configured to be of any shape, including square, rectangular, circular, or other geometric configurations, is mountable within the enclosure of the energy storage system using a fastener or press fit mechanism, and is configured to achieve an ingress protection, IP, rating selected from IP64, IP65, IP67, IP68, or IP69, depending on the specific application requirements.

11. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the housing (102) is constructed from one or more materials including plastic, metal, or a combination thereof, and wherein the housing (102) includes a sealing ring (114) positioned to secure the housing to a mating part of the energy storage system (1000), the sealing ring (114) is configured to provide environmental isolation and structural stability.

12. The breather or vent cap assembly (100) according to any of the preceding claims, wherein the breather or vent cap assembly (100) is powered by the battery of the energy storage system (1000) to which it is attached to.

13. A system (700) for monitoring an energy storage system, characterisedinth a t, the system comprising:the breather or vent cap assembly (100) of any of claims 1-12;a processor (702) communicatively connected to the PCBA (106), configured to:receive sensor data from the breather or vent cap assembly (100) comprising one or more sensors (108), or a combination of different sensor types configured to monitor environmental parameters;execute algorithms to analyze the sensor data for detecting thermal runaway conditions and predicting maintenance requirements based on the monitored environmental parameters; andgenerate alerts or control signals based on the analysis.

14. A computer program comprising instructions which, when executed by a processor, cause the processor to perform a method (800) for monitoring an energy storage system, characterisedinthat, the method comprising:receiving (802) sensor data from a breather or vent cap assembly (100) comprising one or more sensors (108), or a combination of different sensor types configured to monitor environmental parameters;analyzing (804a) the sensor data to detect thermal runaway conditions and5 predicting (804b) maintenance needs based on the monitored environmental parameters; andgenerating (806) alerts or control signals based on the analysis.

15. A computer-readable storage medium having stored thereon the computer program of claim 14.

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