Battery cell with a thermal runaway propagation management system and method of manufacturing same

A vehicle, comprising:

• a vehicle body;
• a battery pack including one or more battery modules and coupled to the vehicle body;
• and
• one or more prismatic battery cells arranged in the one or more battery modules, comprising:
• a prismatic can defining a chamber;
• a first terminal and a second terminal each coupled to the prismatic can;
• a vent coupled to the prismatic can in fluid communication with the chamber;
• battery internals arranged in the chamber comprising at least one jelly roll;
• and
• a thermal runaway propagation (TRP) management system comprising:
• a bladder defining a bladder volume and arranged in the chamber with respect to the at least one jelly roll,
• a port coupled to the prismatic can and in fluid communication with the bladder, and
• a fluid comprising a low boiling point at least partially filling the bladder during normal cell operation.

A method of manufacturing a prismatic battery cell, comprising:

• arranging one or more jelly rolls in a prismatic can;
• arranging a bladder in the prismatic can with respect to the one or more jelly rolls;
• filling the bladder with a fluid via a fill port;
• pressurizing the bladder so that the bladder exerts a bladder force on the one or more jelly rolls and the prismatic can;
• applying a mechanical force on the prismatic can opposite the bladder force;
• completing a formation procedure for developing one or more protective layers on electrodes of the one or more jelly rolls;
• removing at least some of the fluid from the bladder via the fill port;
• and
• sealing the bladder so that the bladder is configured to operate as a thermal runaway propagation (TRP) management system.