US-20260128449-A1 - BATTERY PACK FOAM SHIELD ASSEMBLY

Abstract

A battery pack assembly includes an enclosure assembly that provides an interior area. Battery cells are disposed along an array axis and are positioned within the interior area. Each of the battery cells includes at least one tab terminal that projects outward from the array axis. A shield assembly includes a foam secured to a support rod. The shield assembly is alongside the battery cells within the interior area.

Inventors

• Bhaskara Rao Boddakayala
• Di Zhu

Assignees

• FORD GLOBAL TECHNOLOGIES, LLC

Dates

Publication Date

20260507

Application Date

20241104

Claims (19)

1. 1 . A battery pack assembly, comprising: an enclosure assembly that provides an interior area; a plurality of battery cells disposed along an array axis and disposed within the interior area; each of the plurality of battery cells including at least one tab terminal that projects outward from the array axis; and a shield assembly including a foam secured to a support rod, the shield assembly alongside the plurality of battery cells within the interior area.
2. 2 . The battery pack assembly of claim 1 , wherein the shield assembly is between the plurality of battery cells and at least one busbar.
3. 3 . The battery pack assembly of claim 2 , further comprising a frame providing at least one slot that receives a portion of the at least one tab terminal, and at least one busbar secured to the frame, the frame disposed between the at least one busbar and the shield assembly.
4. 4 . The battery pack assembly of claim 3 , wherein the shield assembly is secured directly to the frame.
5. 5 . The battery pack assembly of claim 1 , wherein the shield assembly includes at least one alignment foot.
6. 6 . The battery pack assembly of claim 1 , wherein the foam is tapered.
7. 7 . The battery pack assembly of claim 1 , wherein the shield assembly includes at least one additive agent that is configured to release in response to a thermal event proximate the shield assembly.
8. 8 . The battery pack assembly of claim 7 , wherein the at least one additive agent is mixed with the foam.
9. 9 . The battery pack assembly of claim 7 , wherein the at least one additive agent comprises silica, aerogel, mica, basalt, or some combination of these.
10. 10 . The battery pack assembly of claim 7 , wherein the at least one additive agent is configured to electrically isolate, block a transfer of thermal energy, or both.
11. 11 . The battery pack assembly of claim 7 , wherein the at least one additive agent comprises melamine poly(zinc phosphate).
12. 12 . The battery pack assembly of claim 1 , wherein the support rod is a polymer-based material.
13. 13 . The battery pack assembly of claim 1 , wherein at least one end portion of the support rod protrudes outside the foam.
14. 14 . The battery pack assembly of claim 1 , wherein the foam is a precast foam.
15. 15 . A battery pack assembly, comprising: an enclosure assembly that provides an interior area; a plurality of battery cells disposed along a array axis and disposed within the interior area; each of the plurality of battery cells including at least one tab terminal that projects outward from the array axis; and a shield assembly including a foam and at least one additive agent dispersed within the foam.
16. 16 . The battery pack assembly of claim 15 , wherein the foam is a precast foam.
17. 17 . The battery pack assembly of claim 15 , wherein the foam of the shield assembly is supported on a support rod of the shield assembly.
18. 18 . The battery pack assembly of claim 15 , wherein the at least one additive agent is configured to electrically isolate, block a transfer of thermal energy, or both.
19. 19 . The battery pack assembly of claim 15 , wherein the at least one additive agent comprises melamine poly(zinc phosphate).

Description

TECHNICAL FIELD This disclosure relates generally to a shield assembly used within a battery pack and, more particularly, to a shield assembly that incorporates foam along with a support rod, additive agent, or both. BACKGROUND A high voltage traction battery pack can power the electric machines and other electrical loads of an electrified vehicle. The traction battery pack can include a plurality of individual battery cells. The traction battery pack can, from time to time, experience a thermal event where one or more of the battery cells vent and expel battery vent byproducts. The vent byproducts can include gases and effluent particles. SUMMARY In some aspects, the techniques described herein relate to a battery pack assembly, including: an enclosure assembly that provides an interior area; a plurality of battery cells disposed along an array axis and disposed within the interior area; each of the plurality of battery cells including at least one tab terminal that projects outward from the array axis; and a shield assembly including a foam secured to a support rod, the shield assembly alongside the plurality of battery cells within the interior area. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the shield assembly is between the plurality of battery cells and at least one busbar. In some aspects, the techniques described herein relate to a battery pack assembly, further including a frame providing at least one slot that receives a portion of the at least one tab terminal, and at least one busbar secured to the frame, the frame disposed between the at least one busbar and the shield assembly. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the shield assembly is secured directly to the frame. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the shield assembly includes at least one alignment foot. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the foam is tapered. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the shield assembly includes at least one additive agent that is configured to release in response to a thermal event proximate the shield assembly. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the at least one additive agent is mixed with the foam. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the at least one additive agent includes silica, aerogel, mica, basalt, or some combination of these. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the at least one additive agent is configured to electrically isolate, block a transfer of thermal energy, or both. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the at least one additive agent includes melamine poly(zinc phosphate). In some aspects, the techniques described herein relate to a battery pack assembly, wherein the support rod is a polymer-based material. In some aspects, the techniques described herein relate to a battery pack assembly, wherein at least one end portion of the support rod protrudes outside the foam. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the foam is a precast foam. In some aspects, the techniques described herein relate to a battery pack assembly, including: an enclosure assembly that provides an interior area; a plurality of battery cells disposed along a array axis and disposed within the interior area; each of the plurality of battery cells including at least one tab terminal that projects outward from the array axis; and a shield assembly including a foam and at least one additive agent dispersed within the foam. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the foam is a precast foam. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the foam of the shield assembly is supported on a support rod of the shield assembly. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the at least one additive agent is configured to electrically isolate, block a transfer of thermal energy, or both. In some aspects, the techniques described herein relate to a battery pack assembly, wherein the at least one additive agent includes melamine poly(zinc phosphate). The embodiments, examples and alternatives of the preceding paragraphs, the claims, or the following description and drawings, including any of their various aspects or respective individual features, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible. DESCRIPTION OF THE FIGURES The variou