IP Library › Granted Patent US 12676376
Granted Patent B2
US 12676376 · App. 17/514,339 · Granted Jul 7, 2026

Traction battery pack enclosure assemblies with integrated thermal barrier systems

Inventors: Bhaskara Rao Boddakayala (Troy, MI); Sudhakar Nandam (Canton, MI)
Assignee: FORD GLOBAL TECHNOLOGIES, LLC
H01M50/233H01M50/204H01M50/249H01M50/271H01M50/502H01M2220/20
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Quick Facts
Patent No.
US 12676376
App. No.
17/514,339
Granted
Jul 7, 2026
Kind
B2
Abstract

Traction battery pack designs for use in electrified vehicles may include a thermal barrier system adapted for mitigating thermal propagation inside of the traction battery pack during battery thermal events. The thermal barrier system may include features such as a bifurcation structure and/or a canopy structure. The bifurcation structure is adapted for substantially isolating a first portion of an enclosure interior where a first battery internal component (e.g., a first battery array) resides from a second portion of the enclosure interior where a second battery internal component (e.g., a second battery array) resides, and the canopy structure is adapted for protecting a bus bar assembly of the traction battery pack.

Claims (24)

1 . A battery pack, comprising:

an enclosure assembly;

a first battery array housed within the enclosure assembly;

a second battery array housed within the enclosure assembly;

a bus bar assembly configured to electrically couple the first and second battery arrays,

wherein the enclosure assembly includes a thermal barrier system adapted to minimize thermal propagation within an interior of the enclosure assembly during a battery thermal event,

wherein the thermal barrier system includes a canopy structure arranged to cover a first portion of the bus bar assembly that is attached to a first terminal of the first battery array and a second portion of the bus bar assembly that is attached to a second terminal of the second battery array.

2 . The battery pack as recited in claim 1 , wherein the enclosure assembly includes a tray and a cover, and further wherein the thermal barrier system protrudes from an inner surface of the cover.

3 . The battery pack as recited in claim 1 , wherein the canopy structure includes a first arm that is arranged to cover the first portion of the bus bar assembly and a second arm that is arranged to cover the second portion of the bus bar assembly.

4 . The battery pack as recited in claim 3 , wherein the first arm includes a first angled tip portion that is angled toward the first battery array and a second angled tip portion that is angled toward the second battery array.

5 . The battery pack as recited in claim 4 , wherein the first angled tip portion includes a first outer foam layer that is received in abutting contact with an upper surface of the first battery array, and the second angled tip portion includes a second outer foam layer that is received in abutting contact with an upper surface of the second battery array.

6 . The battery pack as recited in claim 1 , wherein the thermal barrier system includes a bifurcation structure that extends between the first battery array and the second battery array.

7 . The battery pack as recited in claim 6 , wherein the bifurcation structure isolates a first portion of the interior where the first battery array resides from a second portion of the interior where the second battery array resides.

8 . The battery pack as recited in claim 6 , wherein the bifurcation structure includes an outer foam layer that is received in abutting contact with an upper platform of a mounting structure that extends between the first battery array and the second battery array.

9 . The battery pack as recited in claim 6 , wherein the bifurcation structure straddles a mounting structure that extends between the first battery array and the second battery array.

10 . A battery pack, comprising:

an enclosure assembly including a tray and a cover securable to the tray to establishing an interior;

a first battery array housed within the interior of the enclosure assembly;

a second battery array housed within the interior of the enclosure assembly;

a bus bar assembly configured to electrically couple the first and second battery arrays,

a mounting structure protruding from the tray and disposed axially between the first battery array and the second battery array; and

a thermal barrier system adapted to minimize thermal propagation within the interior of the enclosure assembly during a battery thermal event,

wherein the thermal barrier system includes a base that protrudes inwardly from an inner surface of the cover, a bifurcation structure that extends from the base to a position between the first battery array and the second battery array and is either received in abutting contact with or straddles an upper platform of the mounting structure, and a canopy structure including a first arm that extends in a first direction away from the base and is arranged to cover a first portion of the bus bar assembly that is attached to a first terminal of the first battery array and a second arm that extends in a second direction away from the base and is arranged to cover a second portion of the bus bar assembly that is attached to a second terminal of the second battery array.

11 . The battery pack as recited in claim 10 , wherein each of the cover, the base, the bifurcation structure, and the canopy structure is comprised of a glass fiber reinforce thermoplastic material that is impregnated with an intumescent material.