Abstract: A battery pack assembly includes, among other things, a first battery component, a different, second battery component and an enclosure that has a cover secured to a tray to provide an interior. The first and second battery components are disposed within the interior. The cover has a first area that is disposed directly above the first battery component. The cover has a second area that is disposed directly above the second battery component. The battery pack assembly further includes a rib of the cover. The rib extends into the interior from the first area. The rib is configured to contact the first battery component to inhibit relative movement of the second area toward the second battery component.

Abstract: A porous carbon material includes a hierarchical porous structure including a primary microporous structure and at least one of a secondary mesoporous structure and a secondary macroporous structure. The porous carbon material is formed by combining a halogenated-hydrocarbon, an aprotic hydrocarbon solvent, and a reductant to initiate a reaction that forms intermediate particles having a microporous framework; and subjecting the intermediate particles to a heat treatment at a heat treatment temperature ranging from about 300° C. to less than 1,500° C. for a heat treatment time period ranging from about 20 minutes to about 10 hours to thereby form the porous carbon material. The aprotic hydrocarbon solvent is selected from the group consisting of toluene, hexane, cyclohexane, and combinations thereof.

Abstract: A traction battery assembly includes, among other things, a plurality of battery cells disposed along an axis, an endplate at an axial end of the plurality of battery cells, and a corrugated area of the endplate. The corrugated area has a plurality of corrugations that flatten to accommodate expansion of the plurality of battery cells along the axis.

Abstract: A battery pack assembly includes, among other things, a first battery component, a different, second battery component and an enclosure that has a cover secured to a tray to provide an interior. The first and second battery components are disposed within the interior. The cover has a first area that is disposed directly above the first battery component. The cover has a second area that is disposed directly above the second battery component. The battery pack assembly further includes a rib of the cover. The rib extends into the interior from the first area. The rib is configured to contact the first battery component to inhibit relative movement of the second area toward the second battery component.

Abstract: This disclosure relates to a motor vehicle including a bolt configured to increase the ease of releasing a connection between a battery and a vehicle frame, and a corresponding method. An example vehicle includes a frame, a battery mounted to the frame, and a fastener forming a connection of the battery to the frame. A section of the fastener is configured to increase the ease of releasing the connection.

Abstract: This disclosure relates to a motor vehicle including a bolt configured to increase the ease of releasing a connection between a battery and a vehicle frame, and a corresponding method. An example vehicle includes a frame, a battery mounted to the frame, and a fastener forming a connection of the battery to the frame. A section of the fastener is configured to increase the ease of releasing the connection.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include an enclosure assembly, one or more battery internal components (e.g., battery arrays, battery electronic components, or both) inside the enclosure assembly, and a structural brace outside of the enclosure assembly. The battery internal component may be mechanically coupled to the structural brace while also being mechanically decoupled from the enclosure assembly.

Abstract: A busbar assembly includes, among other things, a busbar, a battery terminal, and a deformed area securing together the busbar and the battery terminal. A securing method includes, among other things, positioning a first portion of an attachment structure within an aperture, deforming a second portion of the attachment structure to provide a deformed area, and using the deformed area to secure a busbar relative to a battery terminal.

Abstract: A busbar assembly includes, among other things, a busbar, a battery terminal, and a deformed area securing together the busbar and the battery terminal. A securing method includes, among other things, positioning a first portion of an attachment structure within an aperture, deforming a second portion of the attachment structure to provide a deformed area, and using the deformed area to secure a busbar relative to a battery terminal.

Abstract: A mounting bracket is provided for a vehicle battery system with a battery tray sized to receive a traction battery. The bracket has first and second sides extending between first and second ends. The bracket defines first and second apertures adjacent to the first end and positioned to cooperate with the first and second bosses to connect the bracket to the battery tray. The bracket defines a third aperture adjacent to the second end and positioned to cooperate with a mounting point on a vehicle frame. The bracket defines a transverse slot intersecting the first side and extending towards the second side, with the transverse slot positioned between the first and third apertures. A vehicle and a vehicle battery system with the mounting bracket are also provided.

Abstract: A vehicle underbody includes a battery pack surrounded by an enclosure, and a bracket. The bracket has first and second flanges disposed in a parallel arrangement, and includes a plate having a wall configured to, in response to an impact, rupture at a trigger to allow the enclosure to move away from an impact direction and deform the first flange. The wall is disposed at angle relative to the flanges, and defined such that impact energy is absorbed by the wall and first flange. The first flange, during an impact, moves toward the second flange, which maintains attachment to the vehicle underbody to absorb energy.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include an enclosure assembly, one or more battery internal components (e.g., battery arrays, battery electronic components, or both) inside the enclosure assembly, and a structural brace outside of the enclosure assembly. The battery internal component may be mechanically coupled to the structural brace while also being mechanically decoupled from the enclosure assembly.

Abstract: Methods for making electroactive composite materials for electrochemical cells are provided. The method includes introducing a particle mixture comprising a first particle having a first diameter (R1) and comprising a first electroactive material and a second particle having a second diameter (R2) smaller than the first diameter (R1) and comprising a second electroactive material into a dry-coating device having a rotatable vessel defining a cavity and a rotor disposed therewithin. The vessel is rotated at a first speed in a first direction, and the rotor is rotated at a second speed greater than the first speed in a second direction opposing the first direction. The particle mixture flows between cavity walls and the rotor and experiences thrusting and compression forces that create a substantially uniform coating comprising the second electroactive material on one or more exposed surfaces of the first particle.

Abstract: A porous carbon material includes a hierarchical porous structure including a primary microporous structure and at least one of a secondary mesoporous structure and a secondary macroporous structure. The porous carbon material is formed by combining a halogenated-hydrocarbon, an aprotic hydrocarbon solvent, and a reductant to initiate a reaction that forms intermediate particles having a microporous framework; and subjecting the intermediate particles to a heat treatment at a heat treatment temperature ranging from about 300° C. to less than 1,500° C. for a heat treatment time period ranging from about 20 minutes to about 10 hours to thereby form the porous carbon material. The aprotic hydrocarbon solvent is selected from the group consisting of toluene, hexane, cyclohexane, and combinations thereof.

Abstract: An adsorption storage tank for a natural gas includes a pressurizable tank disposed on a vehicle to contain the natural gas. A natural gas adsorbent is disposed in the tank. The natural gas is a mixture of constituents having a constituent statistical distribution of molecule lengths and kinetic diameters. The adsorbent has a pore size statistical distribution of pore sizes to adsorb and desorb the mixture of constituents.

Abstract: In an example of a method, a halogenide-hydrocarbon, an aprotic hydrocarbon solvent, and a reductant are combined to initiate a reaction that forms intermediate particles having a microporous framework. The intermediate particles are subjected to a heat treatment at a heat treatment temperature ranging from about 300° C. to less than 1500° C. for a heat treatment time period ranging from about 20 minutes to about 10 hours to form a precursor to microporous carbon.

Abstract: A vehicle underbody includes a battery pack surrounded by an enclosure, and a bracket. The bracket has first and second flanges disposed in a parallel arrangement, and includes a plate having a wall configured to, in response to an impact, rupture at a trigger to allow the enclosure to move away from an impact direction and deform the first flange. The wall is disposed at angle relative to the flanges, and defined such that impact energy is absorbed by the wall and first flange. The first flange, during an impact, moves toward the second flange, which maintains attachment to the vehicle underbody to absorb energy.

Abstract: Methods for making electroactive composite materials for electrochemical cells are provided. The method includes introducing a particle mixture comprising a first particle having a first diameter (R1) and comprising a first electroactive material and a second particle having a second diameter (R2) smaller than the first diameter (R1) and comprising a second electroactive material into a dry-coating device having a rotatable vessel defining a cavity and a rotor disposed therewithin. The vessel is rotated at a first speed in a first direction, and the rotor is rotated at a second speed greater than the first speed in a second direction opposing the first direction. The particle mixture flows between cavity walls and the rotor and experiences thrusting and compression forces that create a substantially uniform coating comprising the second electroactive material on one or more exposed surfaces of the first particle.

Abstract: Examples of battery pack systems that include polymers are a cooling system, a thermal management system, and a liquid leakage control system. The cooling system and the thermal management systems may include an upper critical solution temperature polymer or a lower critical solution temperature polymer. The liquid leakage control system includes a superabsorbent polymer.

Abstract: In an example of a method, a halogenide-hydrocarbon, an aprotic hydrocarbon solvent, and a reductant are combined to initiate a reaction that forms intermediate particles having a microporous framework. The intermediate particles are subjected to a heat treatment at a heat treatment temperature ranging from about 300° C. to less than 1500° C. for a heat treatment time period ranging from about 20 minutes to about 10 hours to form a precursor to microporous carbon.