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  • Patent US8932739B2 Battery Pack Configuration

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    Battery Pack Configuration to Reduce Hazards Associated With Internal Short Circuits By Tesla Motors, Inc.

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    Battery Pack Configuration to Reduce Hazards Associated With Internal Short Circuits By Tesla Motors, Inc.

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    © All Rights Reserved
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    14 views13 pages

    Patent US8932739B2 Battery Pack Configuration

    Uploaded by

    OleleOle
    Battery Pack Configuration to Reduce Hazards Associated With Internal Short Circuits By Tesla Motors, Inc.

    Copyright:

    © All Rights Reserved
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    «2 United States Patent wo ro) wo o 21) ) @) wy 3) Hermann et al. BATTERY PACK CONFI REDUCE HAZARDS GURATION TO OCLATED WITH INTERNAL SHORT CIRCUITS Inventors: Weston Arthur Hermann, Palo Alo, CA (US): Seott Ira Kohn, Redwood City, CA (US); David G, Beek, Tiburon, CATS) Assignee: Tesla Motors, Ine, Palo Alto, CA (US) Notice: Subject to any disctaimer,the term of this pateat is extended or adjusted der USC. 184(b) by 634 days Appl. Now 137088444 Filed: Apr. 18, 2011 Prior Publica US 20120034501 A1 Feb. 9, 2012 n Data Related US. Application Data CContinuaton-in-art of application No. 12/850.282, filed on Aug. 4, 2010, now Pa, No. 8.133608. Int. C1, ois 1080 (2006.01), HOM 226 (2006.01), Ho2s 700 (2006.01), us.c, use 429/62; 429/120, 429/160; 429/161; 3200115; 3200133; 320/134 Field of Classification Search Us 429/62, 120, 160-161; 320/118, 134 ‘See application file for complete search history 301 305: US 8,932,739 B2 Jan, 13, 2015 US008932739B2 (10) Patent No.: (45) Date of Patent: 66) References Cited US, PATENT DOCUMENTS 099.986 A $2000 Gashier ta 6548-206 BI 4.2003. Gatshr ta 29/100 20ODODNES7S AL* 72002 Thats 39500 oost233210 Al* 102005 Horie al. ‘2916 S0OTIISSIAT AL* 82007 Stael ea S204 Solomiasse4 AL* 62010 Kreer etl ‘29°50 FOREIGN PATENT DOCUMENTS 2 Horzss6s2 1011990, 2 2U8IS SOE 3 HIDTITO 101999, » HLI320206 111909 2 2oossssed — "3/2008 OTHER PUBLICATIONS uropean Paes Applicaton No. LIQ06442S, Extended European ‘Search Report dated Nov. 14,2011, 6 pages * cited by examiner Primary Examiner — Mibammad Sidiquee (14) Attorney, Agent, or Firm — 1. Richard Soderberg, on ABSTRACT A battery pac, or battery pack module, is provided that is ‘configured to respond tos short circuit of moderate current in ‘amanner that minimizes therisk ofan inital thermal ranaway ‘event propagating throughout the battery pack/batery pack ‘module. In general, the battery packibattery module allows pre-sclectionof which cell ofthe cells comprising the batery ckrbattery pack mode willbe the last cell to respond tthe short cecut. As a resul,a thermal isolation barrier may be used to separate the preselected ell rom the other cells ofthe batten packibattery pack modole, thereby minimizing the risk of excessive heating and extensive collateral damage. 21 Claims, 6 Drawing Sheets 307 9 NY 501 To Load, Additional Battery Modules, etc. 303 US. Patent Jan, 13,2015 Sheet 1 of 6 US 8,932,739 B2 cp FIG. 1 Por US. Patent Jan, 13,2015 Sheet 2 0f 6 US 8,932,739 B2 200 214 y 229 261 204 Prior Art J 207 202 att US. Patent Jan, 13,2015 Sheet 3 of 6 US 8,932,739 B2 301 To Load, Additional Battery Modules, etc. 308 301 To Load, Additional Battery Modules, etc. FIG. 4 US. Patent Jan, 13,2015 Sheet 4 of 6 US 8,932,739 B2 To Load, Additional Battery Modules, etc. Cell ‘B’ FIG. 5 301 To Load, Additional Battery Modules, etc. \ 308 FIG. 6 US. Patent Jan, 13,2015 Sheet Sof 6 US 8,932,739 B2 To Load, Additional Battery Modules, etc To Load, Additional Battery Modules, etc 8015 203 Cell A Cooling System CellB Cooling System FIG. 8 US. Patent Jan, 13,2015 Sheet 6 of 6 US 8,932,739 B2 801>) Cell B Thermal Quenching System T 907 Heat Exchanger 301 Ne 903. Los } To Load, Additional Battery Modules, etc. Cell ‘A’ Cella’ 801 311 | - 803 Cell A Cooling System Cell B Cooling System FIG. 9 US 8,932,739 B2 1 BATTERY PACK CONFIGURATION TO. [REDUCE HAZARDS ASSOCIATED WITH INTERNAL SHORT CIRCUITS (CROSS-REFERENCES TO RELATED 5 “APPLICATIONS. This application is a continuationin-part of U.S. patent application Ser, No. 12/850,282, filed Aug, 4, 2010, the di closure af whichis incorporated erein by reference for any. 1° and all purposes. FIELD OF THE INVENTION ‘The present invention relates generally to battery packs 1s ‘and, moze paticulrly, to batery pack that is designed to ‘mitigate the effets of arcing due to an ternal short cect BACKGROUND OF THE INVENTION ‘There is curently a tend inthe automotive industry to replace combustion engines with electric motors ora com nation of anlectric motor and a combustion engine, thereby substantially reducing the environmental impaet af automo biles by reducing (ie. hybrids) or completely eliminating 2 (ie, electric vehicles) car emissions. This switeh in drive ‘ean technology is not, however, without its technological sburles asthe use of aa eletric motor translates tothe need for inexpensive batteries with high energy densities, ong ‘operating lifetimes, and operable ina wide range of condi tions. Additionally. ts imperative thatthe hatery pack of vehicle pose noundue health heats, ier during vehicleuse ‘or during periods of storage ‘While current rechargeable battery technology is able to ‘meet the demands of the automate industry, the catvely ‘usable nature the chemistries used in such bateries often leads to spevializedhandlingand operating requirements. For «example, rechargeable batteries such as ithium-ion cells tend fo be more prone (0 thennal runaway than primary eels, thermal rnavay occurring when the internal reaction rate ‘nereases tothe point that more heat is being generated than canbe withdraw, leading toa further increase in both reac- tion rate and hext generation. Eventually the amount of gen erated heat is peat enough to lead tothe combustion ofthe ‘battery as well as materials in proximity tothe battery. Ther- ‘mal runaway nay be initiated by ashort cineuit within thecel, improper cell use, physical abuse, manvfacturing defects, ot ‘expose of the cell extreme external temperatures. In the case of battery pack used ia an electric vehicle a severe car crash may simultaneously send multiple cells within the bat- tery pack into thermal runaway: Inorder to prevent overeating due to an inadvertent short, thereby hopefully preventing the occurrence of @ thermal runaway event, conventional battery packs typically position 4 fuse 101 ia series with one, of both interconnects that ss couple the attery pack 103 to the load 108 a shown in FIG. 1. Unfortunatly, as fuse 101 is designed to prevent low resistance, high curent short, it may not open and interrupt sustained current of moderate magnitude suchas that which ‘may oecur duriagan internal batery short lathes situations, 6 the aflecied battery will coatiaue to heat unit a cell-level safety mechanism is activated Conventional cells, especially those prone to thermal run away, (ypically incorporate a variety of diferent safety ‘mechanisms into thecal tself as lustrated in the simplified ‘cross-sectional view provided in FIG. 2. Battery 200 includes cylindrical case 201, an electrode assembly 203, and a cap 8 2 assembly 208. Case 201 stypclly mae ofa meta, such as ‘nickel plated to, that hasbeen selected sch hat it wll not ‘ec wih thebttery materials, eg theelecuoyt, lectnde assembly ec. Typically el casing 201i fabricated in such aay tat the bottom surface 202s integrated int the case, resulting ina seuss lower eel casing. Eleetode assembly 203 is comprised ofan anode shes, a cathode sheet and an Jterposed separator, wound around a center pin 204 to form a jell Typically cater pin2Mishollo, i. itneades avojdrunningitsentire length ths providing pth or gases forme during an over-resstre vento escape the cell via the vent contained within electrode cap assembly 208, An anode lect ab 207 connects the anode electrode ofthe ‘wound electrode assembly tthe negative ermial which or an 18650 ellis ese 201. A cathode tab 209 connects the cathode eleetode ofthe wound eleetade assembly to the stv terminal va cap assembly 208 Typically battery 200 tka includes pir of sults 211/213 located oa either dof electrode assembly 203 0 avoid short iret hetween assembly 208 an case 201 In cll 200, ab 209 is connected 10 cap assembly 208, ‘Which contains acurent interrupt device (C1D)- The purpose ofthe CID isto break the electrical connection beeen the electrode assembly andthe postive teminal 227 i the pres- sure within the cell excedsapreetrmine level. Typically sucha tat of over pressure is indicative of el overcharging andlorofthe cell temperature increasing beyond the intended operating range ofthe cel for exarsple due to an extemely highexteral temperature or duetoa flue within the batery co charging system, Although other CID configurations are ‘Kowa, inthe llusrotd ell he CID i comprised of lower smember 218 and an upper member 216. Members 218 and 216 are elecrally connected, for example via crimping along their ernery witha pot weld. Lower member 215 includes moltipl openings 217, thus insuring that ny res ste changes Within ease 201 are immediately transmitted 9 upper CID member 216. The cenal region of upper CID ‘member 216s cored (not visible EG 2)so that when the presse within the cll exoods the predetemined level the Scored portion of member 216 beaks re thereby disrupting te contimity between the electrode assembly 208 and the ‘raters tering ‘Under arma presse conitons, lower CID masher 218 ‘scouped by a weld 219 to elect ab 209 and upper CID ‘member 216s coupled hy a weld 221 to safety ven 223. ln auton to disrupting the electrical connection to the elec- trode assembly during an overpressure even, the CID in conjuction with safety ven 223i designed to allow the gas to escape the celina somewhat comtlled mannet. Salty vent 228 may include seoring 225 to promote the vent rp- ‘uring inthe event of over pessue “The pepe of CID member: 218216 is eletcally ‘soloed rom he periphery of safety vent 229 by an insulating gasket 226, As aconsoquence the only electrical connection between CID members 218/246 and salty veat 228 is through wekd 21 Solty vent 223i coupled to ator teeming! 227 via a postive temperature coelcient (PTC) current imiting ele ment 229. PTC 229 is designed such that its resisince ‘becomes very high wen the temperature exceeds predeer. ined level, iereby ining shot ier current How. Cap assembly 205 further include second insulating gasket 291 that insulates the elecnaly conductive element ofthe cap assembly from ease 201, Cap assembly 208 shed in place ‘itn case 201 using cimpod region 238, Inadditon tothe incision ofa CID, a PEC and salty reste vent, many cells abo utlize a Separator wiki the US 8,932,739 B2 3 clectrode assembly 208 that is capable of impeding current. flaw once a predetermined temperature is reached. In such a separatorthe material comprising the separators designedto soften upon resching he preset tempertuze (eg, 130°C.) at ‘hich poit the pores close and impede ion and cureat low. $ Unfortunately ifthe temperature of the eell continues to increase, the material comprising the separator will com- pletely melt and break-down, resulting n'a massive internal short that can aecelorte heating, While individual cells may include one or more builtin 10 safety mechanisms, s noted above these safety mechanis ‘are not always elective when the cell is one ofa rge group, ofcells, ie, the batery pack of FIG. 1, Forexample, the CID ‘within a cell typically has a relatively low voltage rating and therefore may besubject to arcing and fre when itatlempsto. 1S ‘open ina igh voltage battery pack. As a sult the coll may eter into state of thermal minaway. Additionally, due tothe ‘excessive heat generated by suchan event, the temperature of adjacent cells within the battery pack will also increase, potentially leading toa cascading effect where the initiation of thermal runaway within a single ell propagates through- ‘out the entre battery pack. In such a situation, not only is power from the battery pack interrupted, but the system, ‘employing the battery pack is more likely to incur extensive collateral damageducto the scaleof thermal rmaway andthe 2 associated release of thermal energy. While itis possible to design a battery pack that minimizes the risks of arcing or «excessive heating, such an approach leads to inereased cost, complexity and weight, all of which may be quite significant ina lage Battery pack such as that employed ina hybrid or an allleirc vehicle. Accordingly: whats nooded isa meansof ‘minimizing the risks associated with an intemal shot cgcuit within a battery pack, while not significantly impacting bat- tery pack manufacturing cost, complexity and weight. The present system provides such a means x“ 8 SUMMARY OF THE INVENTION ‘The present invention provides «battery pac, ora battery pockimodule, that is configured to respond to ashor circuit ‘moderate current in a manner that minimizes the risk of an inital thermal runaway event propagating thoughout the battery pack/hatery pack module, In general, the disclosed systemallows pre-selotionof whichcell or cells)ofthe cells ‘comprising the bartery packbattry pack module will be the lastcells to respond theshor circuit. As result, athermal isolation barrier may be used to separate the presclected cel. (6) from the other cells ofthe battery packbattery pack mosl- tule, thereby minimizing the risk of excessive heating and extensive collateral damage. In one aspect of the iaveaton, a battery pack short circuit ‘management system is provided that includes battery pack ‘comprised of (i) a plurality of ells characterized bya st of ‘operating characteristics, wherein each cell i electrically connected to a fst collector plate and a second collector plate, and wherein each cell includes first internal short circuit safety mechanism configured to aetivate ata fist em perature; and (i) a preselected cell distinguishable from the plurality of cells, wherein the preselected cells electrically connected to the first and second collectors plates, and ‘wherein the preselected cel includes a second intemal shor. circuit safety mechanism configured to sctivate at second temperature, the second temperature being greater than the firttemperatue (for example, by at eat 10°C.) The batery pocksshort circuit management system also includesa thermal isolation system that thermally separates the preselected cell from the plurality of cells, When ativate, the first intertal s 4 shor circuit safety mechanism may decouple the cell with the ctvated safety mechanism from at least one ofthe ist and second collector plates. When activate, the second internal short circuit safety mechanism may prevent curent ow ‘berweea the anode electrode andthe cathode electrode ofthe electrode assembly of the preselected cel. In at least one ‘embodiment, he fis intemal short circuit safety mechanism associated with each ofthe plurality of ellsis comprised of a current intorup device (CID) while the second internal short. circuit safety mechanism associated with the preselected cel is comprised of a separator shutdown melanism, In this cersbodiment, the preselectd cell does notineludeaCID.Inat least one other embodiment, a CID ofa first configuration is {integrated within each of the plurality of cells and a CID of second configurations integrated within the preselected cell, ‘where the CID of the first configuration opens atthe first. ‘temperature andthe CID ofthe second configuration opens a the second, higher temperature. The plurality of cells may be electrically connected in parallel with the preselected cell clectically connected in parallel with te plurality of cel ‘The thennal isolation system may utilize an enclosure, for example an enclosure that is ()febricated from a ceramic ‘material; (ji fabricated inthe form ofa double-walled strue~ ture, for example where the outer wal fabricated from & ‘metal andthe inner wall is fabricated from a non-metal such asa ceramie; (i fabricatedto include an innersurface coated ‘with an intumescent material; (iv) fabricated to include an interior volume a least partially filled witha thermally non- ccondvetive material such as loose ceramic fibers, woven ceramic fibers, loose fiberglass fibers or woven fiberglass fibers; oF (x) fabricated to include a phase change material Te battery pack shor circuit management system may fur- ther include (frst battery cooling system comprised of a first guid coolant contained within a frst coolant line in thermal communication with the plurality of cells and (i) a sevond battery cooling system comprised of «second liquid coolant contained within second coolant lin in thermal ‘communication with the presoleted el, whore the ist and second battery cooling systems are independent of one another. The second coolant Fine may be integrated within at least one wall of the thermal isolation enclosure, The hatery pock shor circuit management system may’ further include a thermal runaway quenching system coupled to the prese= lected cel, for example via the thermal isolation system, and preferably not coupled tothe plurality of call A futher understanding of te nature and advantages ofthe present invention may be realized by reference tothe remain ing portions ofthe specification and the drawings. BRIEF DESCRIPTION OF THE DRAWINGS FIG, 1 illystates a battery pack utilizing a fase in the {ntereonneet between the battery pack and the load in accor. dance wih the prior at, FIG, 2 isa simplified cross-sectional view of « conven ‘ional batey, for example a thium ion battery wi 18650 fomn-fatoe; FIG. 3 provides high-level view of a battery pockw thermal soltion enclosure surrounding the cell ‘been preselected tobe the last coll toresponditoashor cect. event FIG. 4 provides high-level view of battery pack similar to that shown in FIG. 3 except thatthe thermal isolation cnelosure is mounted outside of the battery pack: FIG. § provides high-level view ofa attry pack similar to that shown in FIG. 3 except thatthe thermal isolation enclosure utilizes a double-walled structure: US 8,932,739 B2 5 FIG. 6 provides a high-level view ofa battery pack similar to tat shown in FIG. 3 except that the interior volume of the ‘thermal isolation enclosure is filled with a thermally non- conductive material; FIG. 7 provides ahigh-level view of battery pack similar $ ‘o that shown in FIG. 3 except thatthe interior surfaces of the thermal jsolation enclosure are coated with an intumescent materia; FIG. 8 provides s high-level view ofa battery pack similar to that shown in FIG. 3 that includes an exemplary cooling. 10 system: and IG. 9 provides shigh-Level view ofa battery pack similar to that shown in FIG. 3 that includes an exemplary thermal runaway quenching system, DESCRIPTION OF THE SPECIFIC EMBODIMENTS In the following text the terms “battery”, “ell”, and “ba ‘ery cell” may be used interchangeably and may efe to any of a variety of cilferet cell types, chemistries and configu ‘ations including, bu not Kimite to, ithium ion (etiam, iron phosphate, lithium cobalt oxide, other lithium metal oxides, et), lithium ion polymer, nickel metal hydride, nickel cadmium, nicks! hydrogen, nickel zinc iver zine, or 2 ‘other battry type/confguraton. The term “battery pack” as sed herein refers to multiple individual batteries eletially interconnected o achieve he desired voltage and capacity for 4 pantcular application, where the multiple batteries may be contained within a single piece or mult-piove housing. It should he understood that identical element symbols use on multiple figures refer to the sume component, or compeneats of equal funetionlity: Additionally, the accompanying fig ‘ures are only meant to illustrate, not limi, the scope ofthe invention and should not be considered tobe to scale. As previously described, when a short circuit event does ‘ot cause a system or batery puck level fuse to blow and interrupt the fo of current, for example because the shorts of'a moderate current level, then the system must rely onthe safety mechanisms integrated within te individual cells to couple the cells from the circuit. Unfortunatly, as these safety mechanisms typically have @ relatively low voltage railing in a high voltage battery pack the last safety mecha nism to trigger is likely to subject the corresponding cel to arcing and fire. This, in tum, is likly to cause the cell to enter {ntoastateof thermal runaway, an event which may propagate ‘throughout a conventional battery pack. Accordingly, the present invention allows.ahatery pack, o battery pack mod ‘le, tobe designed so tha particular, prdteined cell of the plurality of clls comprising the pack/module will be the last cello respond tothe short cecut event. By predetermin- ing which of the batery pack’s cells willbe the last cell 0 respond tothe short eieuit, special precautions may be taken ‘o insure that even hiscell enters int thermal runaway, that thermal runaway event will not propagate throughout the s batterypack. Additionally, tisapproach allows the sytem to ‘be designed with minimal precautions takea fr the eemsin- ‘ng cells within the battery pak, thereby potentially offering ‘weight and cost savings. FIG. 3 provides a highevel view of a battery pack 301 utilizing the invention, As deseeibed in further detail below, the present invention may be wlized inany group ofcellsthat are arranged in a parallel configuration, rogardless of the ‘number of ces or whether the group of ells forms te entire batteny pack or only one module ofa plorality of serially interconnected battery modules. Within battery pack 301 are plurality of cells 303, labeled Cell ‘A that are of substan 6 ‘ally the same design and harceriadby the same st of pening characteristic, i, same barley chery, same enemy’ density, same coniguration, same votageeureat charctrinics, te. Adionally thee elle the same internal safety mechanisms, ncling aD. Fach cel 33s electrically conned 1 a pir of eolleior ples 308/306 ‘Tecollsor plats arlectclly connect tothe nnd toad or to anther btery pack module via ines 307308 Altough not shown, ise may be connected to one or bth Tins 307 and 308, for example prior to connection with another tery pci module. In adton to eels 303, barry pack 301 inloes a el 8, labled Cel Cell 309s alo connected in pl tothe lod vi olestoe pies 308306 fn gener, cel 309 sizes the sme design end is characterize hy these set of operating carctritics (i, chemist, energy dni, onfyuraion and vltagefcurent chances) as calls $8, Cel 309s fom cells 33, however, in the desi and confgution ofits intemal safety mech tus, For expen prefered emedimen cel 309 does tn inl «CID. As et while al af the els within eck 30 wil faction similar unter normal operating con- iionscell 309 wll not espondine same yay asco 303 ete ben down ofthe sparstornatrleadng tomas Five electrical shot and typically thermal uy. Te te erator at which th seartor experiences empl ek dwn depends pon the material eomprising the separator although pial itll beset within the range of 130° C.10 190°C. Adina. asthe separators pial only rato 4 votge in the range of 100 30 vos, and given tht his ‘elage maybe only sul ution ofthe voli tell 509 is sbjocted to once ell 8 open, sven afer tho sepa ‘ator shut-down arcing is ikl o oer, casing the tem Pert of el 3091 continu fo increase, hereby esuling In col 309 enfrng io ternal runaway. Noe that fhe Separator within ol 309 is ot desiane to rekon at predetermined temperature, x prceredthecel empertire US 8,932,739 B2 1 ‘will contin to increase until a different safety mechanism, (ex, fse) is activated or until cell 309 enters into a state oF thermal runaway. ‘By preselecting and identifying the cell within the battery pack that wll respond last oa shor eicuit, special precat ‘ions may be taken to thermally isolate this cel, Thermally isolating the cell ie. cell 309, substantially minimizes ifnot altogether eliminates, the risk hat the increased temperature ofthe cell during a short circuit may adversely affect neigh- boring ells. Thermal isolation of cel 309 also eps to Kimi. the type of collateral damage that offen occurs to adjacent ‘materials and components when a cell or cells undergo thet- ‘mal runaway. This aspect ofthe invention illustrated in FG. 3 invshich cell 309s shown housed within thermal isolation fenelosure 311. It will be appreciated that thermal isolation cnelosure M1 may be contsined within hatery pack enelo- sure301, or mounted ouside of battery pack enclosure 301 as shown it FIG. 4, Additionally, it should be understood that While « thermal isolation enclosure 311 is prefered, other ‘means of themmaly isolating the cell are equally aplicableto the invention, For example, the preselected cell may be thet- ‘mally isolating sing a combination of distance and thermal barrios. Thema! isolation enclosure 311 may be made of ay of 2 variety of materials utilizing a variety of enclosure designs, the primary consideration being the design and material's ability 0 thermally isolate cell 309 from is suroundings. ‘Secondary considerations applied othe enclosure design and ‘material selection for enclosure 311 are weight, manulactur- ing complexity, fibrcation cost and material eost, Exemplary cenelosure designs are provided below in FIGS. 7. It should ‘be understood that while these exemplary enclosures are demonstrated on the system configuration shown in FIG. 3, ‘hey are equally applcableto the system configuration shown, in FIG 4inhich thermal isolationenclosure311 is mounted outside of hattery pack enclosure 301. In the enclosure embodiment lusrated in FIGS. 3 and 4, the walls of the enclosure are fabricated from a thermally ‘hon-conductve material with a high meling point, Pefer- ably the material is also elecsically non-condetve. In one configuration, the selected material sa ceramic Inthe embodiment ofthe thermal isolation enclosure ills- ‘rated in FIG. §, enclosure 31 uilizesa double-walled enclo- sure, Preferably outer wall S01 providesa rigid, strong enclo- sure that is relatively easy to incorporate into a vehicle or other batery pack application while inner wall $03 provides superior thermal isolation. In one exemplary design, outer wall $01 is fabricated from a metal, eg, aluminum oF an aluminum alloy, while inner wall $03 is fabricated from 3 ‘material with the desired thermal properties such as a ceramic. Note that walls 501 and S03 may be separate, for ‘example comprising inner and outer enclosures. Altemately, walls $01 and 508 may be fall integrated, for example by applying a coating ofa ceramic or other thermally non-con- ‘ductive material 303 to the iner surfaces ofthe outer enelo- sure walls $01 Twill be appreciated that while FIG. illus ‘wate a dual wall structure, enclosure 311 may be comprised ‘of more than two walls. ‘The embodiment ofthe thermal isolation enclosure ilus- trated in FIG, 6 is similar to that shown in FIGS, 3 and 4, «0 except thatthe interior volume of housing 601 is atleast. parially filled with a thermally non-conductive material 603. ‘that surrounds cell 309 and at least paially fils the void ‘between cell 309 and the interior walls 605 of vessel 601 Material 603 may be comprised of loose ceramic fibers, ‘woven ceramic fibers, loose fibers fibers, woven fiber- lus fibers, ete. Material 603 may be comprised of a phase x“ s 8 change material Ifa woven materials used, preferably itis ‘wapped und cell 19. I loose material used, prefer aby itisblown or injected into vesel 601 ater cel 309 and it’s interonnets are in place within housing 601 Inthe embesinent othe thermal isolation enelosureilos- trate in FIG. 7 the irr surfaces of housing. 701 are coated with an intumescent material 708 Intuneseeat mate- Fal 703 absorbs the thermal energy generated by cell 309 as itoverheats. Once te intumescent material's aetation em- perature is eache, also refered to a the material's sat expansion temperate or “SET, layer 703 will expand snd provide thermal barrier been cel 309 ad housing 704 Profembly the material selected for layer 788 has a SET temperature greater than 150°. for example athe rangeot 200°C. 10 300°C. Iwill be appreciated tere area varity of suitable intumescent materials, for example aaphite- ‘used inumescent material (eg, expandable arphite ina polymere binder, hemmoplsic elastomer, cranie-ased intumescent material, vermiulitelmineral fiber based int escent material and asmoniupolyphospte hase ite smescent materia. By preselectng the cell within Battery pack that wil be thelast cello the pack tobe affected by asbor crit event, ‘ot only ean he peselected cel he located within thermal fsolaton enclosure as deseribed above, but the lected cll com also be inked to a separate cooing system oF them vet quenching system. An exemplary colin system on- figuration is shown in FIG. Band an exesplary quenching stemisshowa in FIG, 9. While the embodiments lutte {in FIGS. 8 and 9 ar bse on the thermal isolation enclosure OofFIG.3,itshoud be understood that they are equally appli cable her enclosure designs (¢. those showin FIGS, 5-7) aswell as oler batterypack configurations such 8 that show ia FIG. 4 As show ia FIG 8, while not rue the preset mene tionallowsiwo diferent cell colng vystemstobe employed, cone used with the mujoriyof ells wiki battery pock 3, ice cells 303, anda diferent cooling systems with the prse- levied eel ofptck 301 ie, cell 309. Alemately. one evoling system may’ Be used wit lof the eal ofthe bate pk, and second, adftonal cooing system may be used anly ‘with the preselected el. Uilzng separate cooling ystems offers several advantages, First i allows the two cooling stems 10 employ diferent cooling rates and, if desired, different cooling methodologies (3 aireoolng versus lig. uid evolng). For example, since cooing system 801i nly ‘ode to ool the cells wii a normal operational tempera turerangeitmay be configured tohaveless cooling capacity, cape cel basis, than cooling system 803 whichis intended {6 coo! call, ie ell M9, experoncing thermal runs: Second ven fooling sytem 803i damage when cel 309 enters into themal runaway, coling system 801 may be conligured to coatiaue operation, this ping to matin cells 308 within a reasonable range of temperatures Tic, sinc the stem ofthe invention designed to maintain cells $MBata loertemperstur than cell 309 during short eeu te coolant conduits associated with cooling sytem 80 do othaveto be designed to withstand the same emperatesas the eolant conduits associated With cooing sytem B03. As 2 result ofthis desig exiblty, itis possible ows Tighter ‘weight materials plastic) fr cooling syste BOL con- duis than fr cooing system 808 (emt. Similac the conus associatd with voling system 808 may be provided ‘with ational protection, for example by being iterated ‘Within the walls of enclosure 311, thereby enabling evoking US 8,932,739 B2 9 system 803 to continue to operate even after the temperature ‘of cel 39 increases well beyond the normal cel operational range Regardless of whether a single cooling system is used to coo! all of the cells within battery pack 301, or one cooling. s system is used To col ells 303 and another cooling system, sed to coo! cel 309 as illustrated in FIG. 8 the present invention also simplifies the use of a thermal runaway quenching system since sucha system would only be neces sary forthe preselevted cell or ces. For example, in the present exemplary system, only cell 309 would have to be coupled to the quenching system, thus minimizing cost, ‘weight and system complexity. FIG. 9 shows the configuration iustrated in FIG. 8 with the addition ofa thermal rusaway quenching system 901. It 1s will be appreciated that the invention is not limited to a specific type of quenching system and that the present crsbodiment is merely intended wo illustate, aot limit, the use of such a system with the present invention. As shown, the quenching system 901 includes a plurality of nozees 903 ‘mounted in proximity tothe preselected cll. ln this embod ‘ment, nozzles 908 are mounted within enclosure 311. Once the temperature ofthe preselected cel, or the temperature within enclosure 311 indicates either the onset of a thermal runaway eventora thermal runaway event inprogress stem 2 901 pumps @ quenching fuid through nozzles 993 ont cel. 309. Altemately, system 901 may be wiggered based on volt- ‘age and current measurements that indicate thatthe CIDs of the other cells have opened. Preferably system 901 recireu lates the quenching id, for example sing pump 905, Typ cally the quenching fluid passes through a heat exchanger 907, for example a radiator or a eat exchanger coupled to ‘nother vehicle cooling system, nat least one preferred con- figuration, cooling system 808 and quenching system 901 are combined into a single temperature control system comte= sponding to cel 309, In the preferred embodiment, and as described in detail above alofthe cells comprising battery pack 301, excepteel. 309, clude a CID. Asa result, cel 309 is preselected to be the lat cell of battery pack 301 to succumb to a moderate current level short. By preselectng cell 309, special recat tions may be taken to insure that ft does enter into thermal runaway. that thermal event wll not propagate throughout the remaining cells of pack 301 or cause undue collateral dam ‘age, While his approach of preselectng one cello bethe last. cel to respond 10a short is preferred, the inventors envision that other techniques may be employed to achieve the same goal, For example, inan alternate embodiment, all ofthe ells ‘Within battery pock 301 include a CID. However, the CIDsin, cells 303 are configured to open at lower temperature and fressue than the CID that corresponds to cell 309. For ‘example, in one embodimeat the CIDs of cells 308 open at pressure that corresponds to a cell temperature of appro ‘mately 120°C. while the CID of eel 309 opens ata pressure that comesponds toa cell temperature of approximately 140° CAs a resul, and as previously deserbed,all ofthe non- isolated cells, i. cells 303, will open prior to cell 309, thereby allowing special precautions tobe taken to thermally isolate cell 309. As willbe understood by those familiar with the at, the present invention may be embodied in other specilic forms ‘without departing fom the spitt or essential characteristics thereof. For example, while the invention has been described {terms of fithium ion cell, the invention isnot so limited Accordingly, the disclosures and descriptions herein are {tended to be lluseative, but nt Limiting ofthe scope f the ‘vention which i et fort ia the following claims. s 10 ‘What i claimed is: 1. A hatter pack short circuit management system, com- rising: «battery pack, comprising ‘plurality of cells each ofwhich characterized bya set ‘ofoperating characterises, wherein eachofsid ells iselectically connected toa first collector plateand a second collector plate, and wherein exch of said plu- rality of cells further comprises a fist intemal short

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