Abstract: A structural assembly for a battery structure includes a lower wall and a pair of cross members. The lower wall is configured to support a cell stack. The cross members are spaced apart from each other in a longitudinal direction of a vehicle. Each cross member supports a respective side of the cell stack and is configured to extend substantially an entire width of the battery structure. Each cross member includes an outer wall, an inner wall, and connecting members that connect the outer wall to the inner wall. The outer wall, the inner wall, and the connecting members cooperate to define an internal cavity. The inner walls of the cross members are secured to the lower wall to form a unitized structure that houses the cell stack.

Abstract: A structural assembly for a battery structure of a vehicle includes a lower wall and a pair of cross members. The lower wall is configured to support a cell stack. The pair of cross members are spaced apart from each other in a longitudinal direction of the vehicle. Each cross member provides lateral support for a respective side of the cell stack and is configured to extend substantially an entire width of a battery enclosure. Each cross member of the pair of cross members includes an outer wall, an inner wall spaced apart from the outer wall, and connecting members. The outer wall, the inner wall, and connecting members cooperate with each other to define an internal cavity. The inner walls of the pair of cross members are secured to the lower wall and slidable relative to the outer walls of the pair of cross members.

Abstract: A structural assembly for a battery structure includes a first shell, a second shell and a cold plate. The first shell includes a first cross member portion providing lateral support for a respective side of a cell stack. The second shell is secured to the first shell to define a unitized structure that houses the cell stack. The second shell includes a second cross member portion providing lateral support for a respective side of the cell stack and is spaced apart along a longitudinal direction of the vehicle relative to the first cross member portion. The cold plate is housed within the unitized structure. Each of the first and second cross member portions includes an outer wall, an inner wall spaced apart from the outer wall, and connecting members that connect the outer wall to the inner wall.

Abstract: An assembly includes a busbar of a traction battery pack, and at least one terminal of a battery cell of the traction battery pack. The at least one terminal is electrically coupled to the busbar. The assembly further includes a thermal exchange plate, and a thermal interface material that communicates thermal energy to the thermal exchange plate from the at least one terminal, from the busbar, or both.

Abstract: Traction battery packs are disclosed for use in electrified vehicles. Exemplary traction battery packs may include an outer enclosure assembly establishing an interior, and a battery array housed within the interior. The outer enclosure assembly includes a multi-layered enclosure cover designed to withstand the high temperature environment of the traction battery pack while also providing weight savings. In some embodiments, the multi-layered enclosure cover is a roll-bonded structure that includes an inner layer, an outer layer, and a mid-layer. The various layers of the roll-bonded structure may be constructed out of various materials.

Abstract: A traction battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a thermal exchange plate having a plurality of coolant channels distributed within the thermal exchange plate according to a first pattern, and a thermal interface material disposed on a surface of the thermal exchange plate according to a second pattern. The first pattern mimics the second pattern.

Abstract: A traction battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a thermal exchange plate having a plurality of coolant channels distributed within the thermal exchange plate according to a first pattern, and a thermal interface material disposed on a surface of the thermal exchange plate according to a second pattern. The first pattern mimics the second pattern.