Corrugated Battery Pack Shield for Cell Vent Byproduct Containment

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Solution Overview

Problem

Existing traction battery packs lack effective shielding mechanisms to manage vent byproducts from battery cells, which can cause damage to surrounding components due to high thermal energy and pressure.

Innovation Solution

Incorporating corrugated shields made of metal or metal alloy between the cell stack and the enclosure assembly to support the cell stack and create coolant channels, while positioning the corrugations away from battery cell vents to prevent direct contact with vent byproducts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a shield is placed between the cell stack and enclosure assembly to protect from vent byproducts, then protection against thermal damage is improved, but device complexity increases

Engineering Contradiction:

Improveprotection from vent byproductsVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The corrugated shield serves multiple functions simultaneously: it protects the enclosure assembly from vent byproducts, provides structural support for the cell stack, and creates coolant channels for thermal management. This multi-functionality resolves the contradiction by reducing the need for separate components while maintaining comprehensive protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The shield utilizes a thin, corrugated metal structure that provides effective protection against vent byproducts while minimizing added complexity and weight. The corrugated design allows the thin structure to maintain structural integrity and create effective coolant channels without requiring thick or complex shielding materials.

Inventive Principle:

Principle #30Flexible shells and thin films

2Strength

If the corrugated shield directly contacts battery cells to provide support, then structural support is improved, but risk of contact with vent byproducts increases

Engineering Contradiction:

Improvecell stack supportVSAvoidexposure to vent byproducts

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The corrugations extend the shield structure in the vertical dimension, creating multiple contact points along the cell stack height. This dimensional extension provides robust structural support while the offset positioning of corrugations from vent locations ensures that support contact does not compromise protection from vent byproducts.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The shield design applies different functional qualities to different regions: corrugated regions provide structural contact and support with offset positioning away from vents, while smooth regions provide thermal management surfaces and enclosure interface areas. This local differentiation resolves the contradiction between support and protection.

Inventive Principle:

Principle #3Local quality

3Temperature

If coolant channels are created by spacing the shield from the enclosure assembly, then thermal management is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvethermal managementVSAvoidspacing accuracy

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The corrugated structure creates coolant channels through its curved, wave-like geometry rather than requiring precise flat spacing. The inherent curvature and dimensional variations in the corrugations naturally form effective coolant flow paths, reducing sensitivity to manufacturing tolerances while maintaining thermal management effectiveness.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The design accepts a range of spacing parameters rather than requiring a single precise value. The corrugated structure maintains effective coolant channel formation across varying spacing conditions, allowing manufacturing flexibility while ensuring thermal management performance through the geometric properties of the corrugations themselves.

Inventive Principle:

Principle #35Parameter changes

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 corrugated shields effectively manage thermal energy and contain vent byproducts, protecting the enclosure assembly from damage and enhancing coolant circulation for efficient thermal management.

Implementation Method 1

immersing at least a portion of a cell stack within a liquid coolant to manage thermal energy within the cell stack

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

communicating the liquid coolant through channels provided by the corrugated sheet

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20260005378A1Corrugated shield for traction battery pack

Publication Date: 2026.01.01 FORD GLOBAL TECH LLC

AI summary

A traction battery pack assembly, includes an enclosure assembly, a cell stack within an interior of the enclosure assembly, and a corrugated shield. The cell stack has one or more battery cells. The corrugated shield is disposed between the cell stack and an area of the enclosure assembly. The corrugated shield can shield the enclosure assembly from vent byproducts.