Manufacturing methods for battery cell support assembly with integrated thermal runaway mitigation

A method of constructing a cell support assembly with thermal runaway mitigation for a multi-cell rechargeable energy storage system (RESS) having a plurality of battery cells with respective cell vents for expelling gases, the method comprising:

• forming a cell holder, wherein the cell holder is configured to support the plurality of battery cells and has a holder body defining a plurality of apertures arranged in rows, and wherein each aperture is configured to align and be in fluid communication with the cell vent of one of the plurality of battery cells;
• arranging the formed cell holder inside a cavity between an upper mold and a lower mold, wherein the cavity defines a first region configured to accommodate the formed cell holder and a second region configured to accommodate a plurality of potting elements, such that each potting element is arranged in one of the plurality of apertures;
• introducing a potting element material into the second region of the cavity;
• curing the potting element material inside the second region of the cavity to incorporate the plurality of potting elements into the formed cell holder, such that each potting element is arranged in one of the plurality of apertures and thereby forms a support sub-assembly;
• separating the upper and lower molds to remove the formed support sub-assembly;
• adhering a plurality of thermal-barrier strips to the formed support sub-assembly to construct the cell support assembly, wherein:
• each thermal-barrier strip extends parallel to a respective row of apertures, such that each potting element is arranged between a respective battery cell and the corresponding thermal-barrier strip and configured to adhere to the battery cell and to the corresponding thermal-barrier strip to maintain position of the battery cell on the formed cell holder;
• and
• each thermal-barrier strip is configured to thermally insulate corresponding battery cells from gases expelled by neighboring battery cells during a thermal runaway.