Many new advanced Li-ion battery systems being developed for large applications such as EVs and PHEVs are using Li-ion pouch cells in which the packaging in which the cell is encased is made from a thin aluminum laminate material. While providing an advantage in energy density and thermal characteristics, pouch cells pose unique safety problems because of the fact that they tend to balloon up rapidly under abuse conditions in which large amounts of gas are generated. Currently there is no practical technology to provide for the controlled release of excess gas that can prevent these cells from exploding and ejecting their contents, including flammable electrolyte. This SBIR project will demonstrate the feasibility of a novel, low cost approach to venting Li-ion pouch cells that have built up excess gas pressure. Success of the approach will greatly increase the safety of these cells and reduce the risk of damage to the entire battery system, benefiting the consumer and enabling more rapid acceptance of environmentally friendly applications like EVs
