Abstract: A traction battery assembly includes, among other things, a battery cell array having a plurality of individual battery cells. The battery cell array usable with a first busbar module having a first arrangement of busbars. The battery cell array is also usable with a second busbar module having a second arrangement of busbars. When the battery cell array is used with the first busbar module, the battery cell array is partitioned into a first number of groups of battery cells in parallel with each other. When the battery cell array is used with the second busbar module, the battery cell array is partitioned into a different, second number of groups of battery cells in parallel with each other.

Abstract: A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, an array of battery cells, with each cell including a terminal, and a busbar assembly having a first busbar component and a second busbar component. Further, each of the terminals are electrically coupled to both the first busbar component and the second busbar component. A method of forming a busbar assembly is also disclosed.

Abstract: A vehicle assembly includes, among other things, a battery array, and an identifier that is associated with the battery array. The identifier is readable by a control module of an electrified vehicle when the battery array is in an installed position within the electrified vehicle.

Abstract: A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, an array of battery cells, with each cell including a terminal, and a busbar assembly having a first busbar component and a second busbar component. Further, each of the terminals are electrically coupled to both the first busbar component and the second busbar component. A method of forming a busbar assembly is also disclosed.

Abstract: A battery interconnect assembly includes, among other things, at least one first sense lead operably coupled to a structure on a first side of an array of battery cells, and at least one second sense lead operably coupled to a structure on a different, second side of the array. The assembly further includes a multi-port connector configured to communicate signals from both the at least one first sense lead and the at least one second sense lead. A battery monitoring method includes, among other things, communicating signals from a plurality of sense leads through a multi-port connector. At least one of the sense leads is operably connected to a first structure on a first side of a battery array, and least one of the sense leads is operably connected to a second structure on a different, second side of the battery array.

Abstract: A covering assembly for a traction battery includes, among other things, a busbar cover that covers a busbar of a battery array, and a terminal cover connected to the busbar cover and moveable back and forth between a closed position and an open position. The terminal cover and cover at least one terminal of the battery array when in the closed position.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery arrays that may be incorporated into electrified vehicle battery packs may include a grouping of battery cells and a circuit connector module configured for electrically connecting the grouping of battery cells. The circuit connector module may include a first bus bar made of a single material and a second bus bar that is fusible and made of at least two dissimilar materials.

Abstract: A method and apparatus includes, among other things, a plurality of battery cells laid next to each other such that cell tabs from one battery cell overlap cell tabs from an adjacent battery cell to form a set of overlapped cell tabs. Each set of overlapped cell tabs are directly joined to each other at a connection interface. A voltage sense circuitry is directly attached to the cell tabs.

Abstract: A vehicle assembly includes, among other things, a battery array, and an identifier that is associated with the battery array. The identifier is readable by a control module of an electrified vehicle when the battery array is in an installed position within the electrified vehicle.

Abstract: An exemplary array activating assembly includes, among other things a disconnect key moveable back and forth between an engaged and a disengaged position relative to a battery array. The disconnect key completes an electrical conductive path of the battery array when in the engaged position. The electrical conductive path is open when the disconnect key is in the disengaged position. An exemplary array activating method includes moving a disconnect key relative to a battery array from a disengaged to an engaged position. The disconnect key completes an electrical conductive path of the battery array when in the engaged position. The disconnect key does not complete the electrical conductive path when in the disengaged position.

Abstract: A covering assembly for a traction battery includes, among other things, a busbar cover that covers a busbar of a battery array, and a terminal cover connected to the busbar cover and moveable back and forth between a closed position and an open position. The terminal cover and cover at least one terminal of the battery array when in the closed position.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a sense lead assembly having a circuit board that is centrally mounted between first and second wiring members (e.g., flat flexibles cables or flat printed circuits). The circuit board establishes a suitable mounting surface for incorporating sense lead fuses into the sense lead assembly. The centralized sense lead fuses provide for simple and reliable servicing of the battery array in response to battery overcurrent conditions.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a sense lead assembly having a circuit board that is centrally mounted between first and second wiring members (e.g., flat flexibles cables or flat printed circuits). The circuit board establishes a suitable mounting surface for incorporating sense lead fuses into the sense lead assembly. The centralized sense lead fuses provide for simple and reliable servicing of the battery array in response to battery overcurrent conditions.

Abstract: A battery pack includes an array frame having a fastener housing, a mounting insert positioned within the fastener housing, and a column bolt extending through the mounting insert. The mounting insert may be secured to a battery pack enclosure structure using one or more fasteners.

Abstract: A battery interconnect assembly includes, among other things, at least one first sense lead operably coupled to a structure on a first side of an array of battery cells, and at least one second sense lead operably coupled to a structure on a different, second side of the array. The assembly further includes a multi-port connector configured to communicate signals from both the at least one first sense lead and the at least one second sense lead. A battery monitoring method includes, among other things, communicating signals from a plurality of sense leads through a multi-port connector. At least one of the sense leads is operably connected to a first structure on a first side of a battery array, and least one of the sense leads is operably connected to a second structure on a different, second side of the battery array.

Abstract: This disclosure relates to a low profile busbar for an electrified vehicle and a corresponding method. In a particular embodiment of the electrified vehicle, an example busbar is electrically connected to two electronic components, and the busbar has a cross-section with a height and a width at least 20 times the height. In this way, the width of the busbar is exaggerated relative to the height, giving the busbar a low profile and making the busbar particularly suited for being routed in spaces with reduced packaging height requirements.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery arrays that may be incorporated into electrified vehicle battery packs may include a grouping of battery cells and a circuit connector module configured for electrically connecting the grouping of battery cells. The circuit connector module may include a first bus bar made of a single material and a second bus bar that is fusible and made of at least two dissimilar materials.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a sense lead assembly having a circuit board that is centrally mounted between first and second wiring members (e.g., flat flexibles cables or flat printed circuits). The circuit board establishes a suitable mounting surface for incorporating sense lead fuses into the sense lead assembly. The centralized sense lead fuses provide for simple and reliable servicing of the battery array in response to battery overcurrent conditions.

Abstract: An exemplary array activating assembly includes, among other things a disconnect key moveable back and forth between an engaged and a disengaged position relative to a battery array. The disconnect key completes an electrical conductive path of the battery array when in the engaged position. The electrical conductive path is open when the disconnect key is in the disengaged position. An exemplary array activating method includes moving a disconnect key relative to a battery array from a disengaged to an engaged position. The disconnect key completes an electrical conductive path of the battery array when in the engaged position. The disconnect key does not complete the electrical conductive path when in the disengaged position.

Abstract: A traction battery includes cells stacked in an array and having terminals, and endplates sandwiching the array. A busbar module extends between the endplates and includes slots and busbars interleaved along a length of the busbar module. The terminals extend through the slots and connect to the busbars. The busbar module includes a pair of end pieces and a center piece that are separately formed and secured together by connection features.