Abstract: A vehicle includes a body including a first frame rail and a second frame rail and a cross-brace directly connected to the first frame rail and the second frame rail. A powertrain-electrification component is supported by the cross-brace. A vehicle subframe is directly connected to the cross-brace. A vehicle-steering gear is connected to the subframe. The direct connection of the subframe to the cross-brace dampens vibration, e.g., road vibration and noise, in the subframe to reduce noise, vibration, and harshness transferred to a vehicle occupant through the vehicle-steering gear.

Abstract: An electrified vehicle assembly according to an exemplary aspect of the present disclosure includes, among other things, a brace assembly that extends from a passenger side frame rail of a vehicle to a driver side frame rail of the vehicle, and at least one electrified vehicle powertrain module supported by the brace assembly.

Abstract: A delivery system includes a processor programmed to construct a route so as to include predefined segments traveled by carriers configured to taxi the vehicle and charge a battery thereof such that a state of charge of the battery remains above a target for a duration of the route, and forward the route to the vehicle.

Abstract: Multi-piece enclosure covers are disclosed for use on traction battery packs that include cell-to-pack battery systems. An exemplary multi-piece enclosure cover may include a plurality of individually removable cover panels. The cover panels may be positioned in a shingled or overlapping fashion relative to one another for covering the cell-to-pack battery system. Each cover panel may be individually removed relative to the remaining cover panels of the enclosure cover for servicing one or more battery internal components of the traction battery pack. The unremoved cover panels may support a portion of the tensile loads acting upon an enclosure tray of the traction battery pack while another cover panel is removed.

Abstract: Retention assemblies are disclosed for retaining a battery cell stack/matrix relative to an enclosure tray on traction battery packs that include cell-to-pack battery systems. The retention assemblies may be positioned between a cell stack/cell matrix and an interior surface of the enclosure tray. The retention assemblies may include features such as slider panels, clips, adhesive, and/or shims designed for holding the cell stacks down at the cell stack-to-enclosure tray interface.

Abstract: Traction battery packs are disclosed that include cell-to-pack battery systems. A cell matrix of the cell-to-pack battery system may be positioned within an enclosure assembly of the traction battery pack. The enclosure assembly may include one or more multi-layered structures. Each multi-layered structure may include a first chamber and a second chamber. The first chamber provides an internal cooling circuit for thermally managing the cell matrix, and the second chamber provides an air gap for insulating the cell matrix from an exterior environment.

Abstract: A battery pack assembly method, including: positioning at least one cell stack within an enclosure structure; moving a compressing wall against the at least one cell stack to a position where the compressing wall applies a compressive force to the at least one cell stack between the enclosure structure and the compressing wall; and securing the compressing wall to hold the at least one cell stack in the position.

Abstract: A traction battery pack assembly includes battery cells, an enclosure tray, an enclosure cover that is secured to enclosure tray to provide an interior area that houses the plurality of battery cells, and an electronics support plate supported by the enclosure cover. A traction battery electronics support method includes positioning battery cells of a traction battery pack within an enclosure tray of the traction battery pack, connecting at least one electronics module electrically to other components of the traction battery pack. After the connecting, the method includes securing an electronics support plate to an enclosure cover of the traction battery pack. The electronics support plate supports the at least one electronics module.

Abstract: A battery pack assembly method includes compressing a first cell stack, compressing a second cell stack, and inserting the first cell stack together with the second cell stack into a cell-receiving opening of an enclosure structure. Another traction battery pack assembly method includes simultaneously inserting a plurality of separate cell stacks into an enclosure structure when the plurality of cell stacks are each compressed by a compression fixture and, after the inserting, compressing the plurality of cell stacks using the enclosure structure.

Abstract: A traction battery pack assembly includes a cell stack disposed along a cell stack axis. A sheet metal enclosure structure holds the cell stack within a cell-receiving area and compresses the cell stack along the cell stack axis. A battery pack assembly method includes forming a sheet metal blank into an enclosure structure having a cell-receiving area, inserting a cell stack into the cell-receiving area of the enclosure structure, and, after the inserting, compressing the cell stack with the enclosure structure.

Abstract: A battery pack assembly method includes holding a cell stack with a compression machine. The compression machine engages a first load plate at a first end of the cell stack and a second load plate at an opposite, second end of the cell stack during the holding. The method further includes aligning the cell stack relative to an enclosure structure while the compression machine holds the cell stack, inserting the cell stack into a cell-receiving opening of an enclosure structure, and disengaging the compression machine from the first load plate and the second load plate.

Abstract: Traction battery packs are disclosed that include cell-to-pack battery systems. A cell stack/cell matrix of the cell-to-pack battery system may be positioned within an irregularly shaped enclosure tray of the traction battery pack. A block insert may be positioned at an interface between the cell stack/cell matrix and an irregularly shaped interior surface of the enclosure tray. The block insert may be configured to facilitate insertion of the cell stack/cell matrix into the enclosure tray, transfer compression loads from the enclosure tray walls to the cell stack/cell matrix, resist battery cell compression loads, etc.

Abstract: Cover attachments are disclosed for securing an enclosure cover to a cell row/battery cell separator on traction battery packs that include cell-to-pack battery systems. One or more separators of a cell-to-pack battery system may be configured to separate cell stack rows or battery cells within the cell-to-pack battery system. A cover attachment (e.g., a clip, an adhesive puck, a magnet assembly, a hook and loop assembly, a ball-and-socket assembly, etc.) may connect to a portion of the separator for securing the enclosure cover directly to the cell-to-pack battery system. The combination of the cover attachments and the separators provides for enclosure cover retention at interior regions of the cell-to-pack battery system, maintains the enclosure cover at a spaced distance apart from the battery cells of the cell-to-pack battery system, and creates a desired amount of pack-level stiffness for distributing loads through the cell-to-pack battery system.

Abstract: A battery pack assembly method includes engaging an enclosure structure with manufacturing equipment, changing a size of a cell-receiving opening in the enclosure structure using the manufacturing equipment, inserting at least one cell stack into the cell-receiving opening, and disengaging the manufacturing equipment from the enclosure structure.

Abstract: A vehicle includes a body including a first frame rail and a second frame rail and a cross-brace directly connected to the first frame rail and the second frame rail. A powertrain-electrification component is supported by the cross-brace. A vehicle subframe is directly connected to the cross-brace. A vehicle-steering gear is connected to the subframe. The direct connection of the subframe to the cross-brace dampens vibration, e.g., road vibration and noise, in the subframe to reduce noise, vibration, and harshness transferred to a vehicle occupant through the vehicle-steering gear.

Abstract: An electrified vehicle assembly according to an exemplary aspect of the present disclosure includes, among other things, a brace assembly that extends from a passenger side frame rail of a vehicle to a driver side frame rail of the vehicle, and at least one electrified vehicle powertrain module supported by the brace assembly.

Abstract: Integrated mounting systems for mounting electric drive components within electrified vehicles may include a cross brace assembly that mounts or supports one or more electric drive components relative to a vehicle frame. A cross brace assembly of the mounting system may include a cross brace, a first bridging side bracket, and a second bridging side bracket. The cross brace may be mounted to lower surfaces of vehicle frame rails and the bridging side brackets may be mounted to upper surfaces of the vehicle frame rails to provide a robust and serviceable mounting solution that evenly distributes vehicle loads.

Abstract: This disclosure details integrated mounting systems for mounting electric drive components within electrified vehicles. An exemplary mounting system may include a cross brace assembly that mounts or supports one or more electric drive components relative to a vehicle frame. A cross brace assembly of the mounting system may include a cross brace, a first bridging side bracket, and a second bridging side bracket. The cross brace may be mounted to lower surfaces of vehicle frame rails and the bridging side brackets may be mounted to upper surfaces of the vehicle frame rails to provide a robust and serviceable mounting solution that evenly distributes vehicle loads.

Abstract: A delivery system includes a processor programmed to construct a route so as to include predefined segments traveled by carriers configured to taxi the vehicle and charge a battery thereof such that a state of charge of the battery remains above a target for a duration of the route, and forward the route to the vehicle.

Abstract: A two-part fastener for an assembly having a sealed joint formed by at least two flanges or sealing surfaces. A first flange defines a first opening, a second flange defines a second opening with a seal being disposed between the first and second flanges. The flanges and seal are secured together with a bolt and a receiver that defines a threaded hole for receiving the bolt. The receiver includes an end face engaging the first flange and a shoulder engaging the second flange. The spacing between the end face and the shoulder defines a gap for the seal. The shoulder of the receiver may include a weld bead that is welded to the second flange. In one embodiment, three flanges are assembled together with a seal between each flange.