Battery Pack Vent Shield Assembly for Cascading Thermal Event Control

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Solution Overview

Problem

Existing battery pack assemblies in electrified vehicles face challenges in managing vent byproducts such as gas and debris effectively, which can lead to thermal events and damage to neighboring cells due to inefficient containment and direction of these byproducts.

Innovation Solution

A polymer-based shield is used within the battery pack enclosure to define channels that receive and direct vent byproducts from battery cells, preventing thermal energy transfer and cascading events, with the shield being less than three millimeters thick and stamped to create specific contact areas and clearance channels for terminals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a shield is added to contain and direct vent byproducts, then thermal energy transfer is prevented and reliability is improved, but device complexity increases

Engineering Contradiction:

Improveprevention of thermal eventsVSAvoidshield structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The shield acts as an intermediary component positioned between the battery cells and the enclosure wall. It intercepts vent byproducts and directs them into channels, preventing direct contact between thermal events and neighboring cells while simplifying the overall containment strategy compared to more complex active cooling or suppression systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The shield is segmented into multiple functional zones: a first region that receives vent byproducts from battery cells, channels that direct the byproducts, and a second region that expels them. This segmentation allows each zone to perform its specific function efficiently, improving thermal management while keeping the overall structure manageable.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If a polymer-based shield is used, then ease of manufacture is improved and device complexity is reduced, but strength and heat resistance may be insufficient

Engineering Contradiction:

Improveshield fabricationVSAvoidthermal and structural strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The shield utilizes a polymer-based material that can be formed into thin, flexible structures. The material is configured with specific geometric features including channels and raised regions that provide structural functionality. The polymer's flexibility allows for complex channel geometries to be integrated into the shield structure, enabling effective byproduct direction while maintaining ease of manufacture.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The shield employs a composite structure combining polymer material with integrated channel geometries and raised regions. This composite approach allows the polymer to provide ease of manufacture and flexibility while the geometric features provide the necessary structural strength and thermal management functionality.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If the shield is made less than three millimeters thick, then weight is reduced and ease of manufacture is improved, but structural strength decreases

Engineering Contradiction:

Improveshield weightVSAvoidstructural support

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The shield incorporates curved channel geometries and raised regions that provide structural reinforcement. The curved surfaces distribute mechanical stresses more effectively than flat surfaces, allowing the thin polymer shield to maintain adequate structural strength while keeping weight low and facilitating manufacturing processes.

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The shield exhibits local quality variations with different regions having different thicknesses and geometric complexities. The channels and raised regions are strategically positioned to provide structural reinforcement where needed, while other areas remain thin to minimize weight. This localized optimization allows the shield to achieve adequate strength with minimal overall thickness.

Inventive Principle:

Principle #3Local quality

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 solution effectively contains and directs vent byproducts, preventing thermal energy transfer and reducing the risk of cascading thermal events, while maintaining structural support and insulation for the battery terminals and cell stacks.

Implementation Method 1

a shield spanning over the first and second battery cell stacks within the interior area, the shield defining a first channel with the first battery cell stack to receive vent byproducts

Methodology Applied

Scientific EffectPhysical Containment: Physical Containment

Data Source

PatentUS20250007083A1Battery pack vent byproduct shield assembly and thermal energy management method

Publication Date: 2025.01.02 FORD GLOBAL TECH LLC

AI summary

A battery pack assembly includes a first battery cell stack, a second battery cell stack, and an enclosure having an interior area. The first and second battery cell stacks are housed within the interior area. A shield spans over the first and second battery cell stacks within the interior area. The shield defines a first channel with the first battery cell stack to receive vent byproducts from at least one battery cell within the first battery cell stack. The shield defines a second channel with the second battery cell stack to receive vent byproducts from at least one battery cell within the second battery cell stack.