Battery pack casing having crush resistance and thermal insulation for electrified vehicle

ChangeBridge: Patent Grants - Batteries (H01M)

Published March 31st, 2026

Detected March 31st, 2026

Summary

The USPTO granted Patent US12592440B2 to FCA US LLC for a battery pack assembly with crush resistance and thermal insulation features for electrified vehicles. The patent covers an air column design within the battery case that mitigates impact damage to the battery housing. Six inventors are credited: Huiyang Yu, Cuicui Zhang, Jingjing Zhao, Gang Wang, Liang Hou, and Caizhen Sun. The patent contains 17 claims.

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What changed

USPTO granted Patent US12592440B2 to FCA US LLC on March 31, 2026, covering a battery pack assembly configured for electrified vehicles. The invention includes a battery case with a bottom surface, forward and rearward walls, and sidewalls, along with a three-tier air column assembly positioned within the case to absorb impact energy. The third-tier air columns engage all four walls of the battery case in the installed position, providing crush resistance and thermal insulation to protect the battery housing. The patent was filed on August 28, 2023, under application number 18456654.

Patent grants do not create immediate compliance obligations for other entities. However, automotive manufacturers and battery system developers should note this patent when designing electrified vehicle battery housings to avoid potential infringement issues. FCA US LLC now holds enforceable patent rights covering this crash-protection and thermal management architecture. No deadlines or penalties apply to this grant notice.

Source document (simplified)

← USPTO Patent Grants

Battery pack casing having crush resistance and thermal insulation for electrified vehicle

Grant US12592440B2 Kind: B2 Mar 31, 2026

Assignee

FCA US LLC

Inventors

Huiyang Yu, Cuicui Zhang, Jingjing Zhao, Gang Wang, Liang Hou, Caizhen Sun

Abstract

A battery pack assembly configured to be coupled to a battery housing for an electrified vehicle includes a battery case and an air column assembly. The battery case has a bottom surface, a forward wall, a rearward wall, a first sidewall and a second sidewall. The air column assembly is supported within the battery case and includes a first, second and third plurality of air columns. The first plurality of air columns are positioned along the bottom surface of the battery case. The second plurality of air columns are positioned outboard of the first plurality of air columns. The third plurality of air columns are positioned outboard of the second plurality of air columns and engage the forward wall, rearward wall, first sidewall and second sidewall of the battery case in an installed position. The battery case assembly mitigates impact damage to the battery housing in the installed position.