Battery Pack Casing Air Columns for Crush and Thermal Protection

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Solution Overview

Problem

Conventional battery pack housings in electrified vehicles suffer from deformation and damage due to vehicle impacts and lack thermal insulation, with existing metal protection plates being costly and ineffective.

Innovation Solution

A battery case assembly incorporating strategically placed air columns made of flexible silicone material that provides impact protection and thermal insulation by distributing and absorbing forces, while nesting around the battery pack housing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal protection plates are used to protect battery pack housing from impact, then impact resistance is improved, but cost increases and thermal insulation is not provided

Engineering Contradiction:

Improveimpact resistanceVSAvoidcost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent uses air columns (pneumatic elements) as the primary protective mechanism. The air columns are compressible and can absorb impact forces through deformation, providing impact protection without requiring solid metal plates. This pneumatic approach reduces cost while maintaining protective functionality.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The patent employs a composite structure combining air columns with housing material (plastic or metal). The air columns act as a cushioning layer between the housing and external impacts, creating a composite protective system that is both cost-effective and thermally insulating while providing adequate impact resistance.

Inventive Principle:

Principle #40Composite materials

2Strength

If metal protection plates are used to protect battery pack housing from impact, then impact resistance is improved, but thermal insulation capability is not provided

Engineering Contradiction:

Improveimpact resistanceVSAvoidthermal insulation

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The air columns trapped within the housing create a pneumatic insulation barrier. Air is a poor thermal conductor, so the columns of air provide thermal insulation between the battery components and the external environment, addressing the thermal management requirement that metal plates fail to provide.

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The air columns create an inert thermal environment around the battery components. The trapped air acts as a thermal barrier, isolating the batteries from extreme external temperatures and providing passive thermal management without requiring active cooling systems.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

3Ease of manufacture

If conventional battery pack housing is used without additional protection, then cost is reduced, but deformation and damage occur due to vehicle impacts

Engineering Contradiction:

ImprovecostVSAvoidprotection from impact damage

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The air columns are pre-positioned within the housing structure before the battery is installed. These columns are already in place to provide cushioning and protection against upcoming impacts, such as road debris or parking lot obstacles. This beforehand cushioning approach provides reliable protection without adding significant cost to the basic housing structure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The air column design effectively mitigates impact damage and enhances thermal management, extending the life of battery components and reducing weight and cost.

Implementation Method 1

strategically placed air columns made of flexible silicone material that provides impact protection and thermal insulation by distributing and absorbing forces

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

strategically placed air columns made of flexible silicone material that provides impact protection and thermal insulation

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12592440B2Battery pack casing having crush resistance and thermal insulation for electrified vehicle

Publication Date: 2026.03.31 FCA US LLC

AI summary

A battery pack assembly configured to be coupled to a battery housing for an electrified vehicle includes a battery case and an air column assembly. The battery case has a bottom surface, a forward wall, a rearward wall, a first sidewall and a second sidewall. The air column assembly is supported within the battery case and includes a first, second and third plurality of air columns. The first plurality of air columns are positioned along the bottom surface of the battery case. The second plurality of air columns are positioned outboard of the first plurality of air columns. The third plurality of air columns are positioned outboard of the second plurality of air columns and engage the forward wall, rearward wall, first sidewall and second sidewall of the battery case in an installed position. The battery case assembly mitigates impact damage to the battery housing in the installed position.