Battery pack assembly having a thermal barrier and method of thermal control within a battery pack

Patent metadata

Field	Value
Publication number	US-12482880-B2
Application number	US-202217845077-A
Country	US
Kind code	B2
Filing date	Jun 21, 2022
Priority date	Jun 21, 2022
Publication date	Nov 25, 2025
Grant date	Nov 25, 2025

Abstract

A battery pack assembly includes a first battery array, a second battery array adjacent the first battery array, and a thermal barrier assembly that blocks transfer of thermal energy between the first battery array and the second battery array. The thermal barrier assembly having a sheet of material that is folded to provide a plurality of layers.

First claim

What is claimed is:

1 . A battery pack assembly, comprising:
a first battery array; a second battery array adjacent the first battery array; and a thermal barrier assembly that blocks transfer of thermal energy between the first battery array and the second battery array, the thermal barrier assembly having a sheet of material that is folded to provide a plurality of layers, wherein some of the plurality of layers are undersized relative other layers of the plurality of layers to provide a notch within the thermal barrier assembly, the notch configured to accommodate a component of a battery pack.

2 . The battery pack assembly of claim 1 , wherein the sheet of material comprises felt.

3 . The battery pack assembly of claim 1 , wherein the sheet of material comprises oxidized polyacrylonitrile fibers.

4 . The battery pack assembly of claim 1 , wherein the sheet of material is accordion folded.

5 . The battery pack assembly of claim 1 , wherein the plurality of layers comprises more than two layers.

6 . The battery pack assembly of claim 1 , further comprising at least one fastener that extends through the plurality of layers.

7 . The battery pack assembly of claim 6 , wherein the at least one fastener is a tag fastener.

8 . The battery pack assembly of claim 7 , wherein the at least one fastener has an “I” shape.

9 . The battery pack assembly of claim 1 , further comprising an enclosure housing the first battery array, the second battery array, and the thermal barrier assembly.

10 . The battery pack assembly of claim 9 , wherein the thermal barrier assembly is compressed by a portion of the enclosure.

11 . The battery pack assembly of claim 10 , wherein the portion that compresses the thermal barrier assembly is a cover of the thermal barrier assembly.

12 . The battery pack assembly of claim 1 , wherein the component is a busbar.

13 . A battery pack assembly, comprising:
a first battery array; a second battery array adjacent the first battery array; and a thermal barrier assembly that blocks transfer of thermal energy between the first battery array and the second battery array, the thermal barrier assembly having a sheet of material that is folded to provide a plurality of layers, wherein at least one of the plurality of layers is undersized relative to other layers to define a recess, the recess configured to receive a component of a battery pack.

14 . The battery pack assembly of claim 13 , wherein the component is a busbar assembly extending between the first battery array and the second battery array.

15 . The battery pack assembly of claim 13 , wherein the sheet of material comprises oxidized polyacrylonitrile fibers.

16 . The battery pack assembly of claim 13 , wherein the thermal barrier assembly is compressed by a portion of an enclosure that houses the thermal battery assembly, the first battery array, and the second battery array.

17 . A battery pack assembly comprising:
a first battery array; a second battery array adjacent to the first battery array; and a thermal barrier assembly disposed between the first battery array and the second battery array, the thermal barrier assembly comprising a sheet of material folded to define a plurality of layers, wherein at least one of the plurality of layers is offset from at least one other layer in the plurality of layers to define a notch, the notch configured to nest a battery pack component such that the component is at least partially surrounded by the plurality of layers of the thermal barrier assembly.

18 . The battery pack assembly of claim 13 , wherein the component is a busbar assembly extending between the first battery array and the second battery array.

19 . The battery pack assembly of claim 13 , wherein the sheet of material comprises oxidized polyacrylonitrile fibers.

20 . The battery pack assembly of claim 13 , wherein the thermal barrier assembly is compressed by a portion of an enclosure that houses the thermal battery assembly, the first battery array, and the second battery array.

Assignees

• Ford Global Tech Llc

Inventors

• Boddakayala Bhaskara Rao
• Utley Brian
• Swoish James Lawrence
• Smith Thomas Edward
• Kotak Nihar

Classifications

• H01M50/262

  with fastening means, e.g. locks · CPC title

• H01M50/271 Primary

  Lids or covers for the racks or secondary casings · CPC title

• H01M50/293

  characterised by the material · CPC title

• H01M50/204

  Racks, modules or packs for multiple batteries or multiple cells · CPC title

• H01M50/24

  adapted for protecting batteries from their environment, e.g. from corrosion (thermal insulation H01M10/658) · CPC title