Abstract: Traction battery packs are disclosed for use in electrified vehicles. An exemplary traction battery pack may include an outer enclosure assembly establishing an interior, and a battery array housed within the interior. A polymer-based enclosure cover of the outer enclosure assembly may be structurally reinforced by one or more structural cross-members. The structural cross members are designed to provide structural integrity during both normal operating conditions and thermal/venting events of the traction battery pack.

Abstract: A battery pack assembly includes a first cell stack having a first side and a second side. The first side is transverse to the second side. A second cell stack is adjacent the first side of first cell stack. A divider has a barrier portion and an attachment portion. The barrier portion is disposed between the first side of the first cell stack and the second cell stack. The attachment portion is secured directly to the second side of the first cell stack.

Abstract: Thermal barrier assemblies are provided for use within traction battery packs. An exemplary thermal barrier assembly may include features for establishing a sealed interface relative to one or more adjacent structures of a traction battery pack. In some implementations, the thermal barrier assembly may provide features for interfacing with cell stack cross-members beams, upper enclosure structures, lower enclosure structures, etc. The sealed interfaces substantially prevent thermal energy from moving from compartment-to-compartment/cell packet-to-cell packet during a battery thermal event.

Abstract: Thermal barrier assemblies are provided for traction battery packs. An exemplary thermal barrier assembly may be configured to block or even prevent thermal energy associated with a battery thermal event from moving from cell-to-cell, compartment-to-compartment, and/or cell stack-to-cell stack within the traction battery pack. The thermal barrier assembly may include a locator configured to locate the thermal barrier assembly relative to a heat exchanger plate of the traction battery pack. The locator may at least partially fill and seal a slot formed in the heat exchanger plate.

Abstract: Thermal barrier assemblies are provided for traction battery packs. An exemplary thermal barrier assembly may be configured to block or even prevent thermal energy associated with a battery thermal event from moving from cell-to-cell, compartment-to-compartment, and/or cell stack-to-cell stack within the traction battery pack. The thermal barrier assembly may include features such as a protective housing and a thermal insulating barrier provided within the protection housing. The protecting housing may be made of a metallic, ceramic, or polymeric material, for example. The thermal insulating barrier may include an aerogel, a foam, or an inorganic paper, for example.

Abstract: A battery pack venting assembly includes a first beam establishing a first side of a passageway and a second beam establishing an opposite, second side of the passageway. The passageway is configured to communicate battery cell vent byproducts. A method of establishing a vent path within a traction battery pack includes, within an enclosure assembly of a battery pack, providing a cross-member assembly having a first beam and a second beam; and communicating battery cell vent byproducts through at least one opening in the first beam into a passageway having a perimeter that is at least partially provided by the first beam and the second beam.

Abstract: A traction battery pack assembly includes a battery pack enclosure that provides an interior area, and at least one cell stack that includes battery cells and at least one divider distributed along a cell stack axis. The at least one divider compartmentalizes the interior area into a plurality of compartments. Each of the compartments holds at least one of the battery cells.

Abstract: A thermal management system for a traction battery pack includes at least one cell stack having a plurality of battery cells, a thermal exchange device having a first plate, a second plate, and at least one coolant passageway that communicates a coolant between the first plate and the second plate. The first plate is a first material. The second plate is a second material that is different than the first material. The thermal management system further includes at least one thermal break in the thermal exchange device. The at least one thermal break configured to inhibit thermal energy transfer from a first area of the thermal exchange device to a different, second area of the thermal exchange device.

Abstract: Structural cross-member assemblies are provided for traction battery packs. An exemplary cross-member assembly may include a cross-member beam having a beam body and at least one reinforcement section that provides structural integrity to the beam body. The reinforcement section may be a pultrusion and may embody various cross-sectional shapes. The cross-member beam may be positioned adjacent to an additional cross-member beam to establish the cross-member assembly disposed between adjacent cell stacks of the traction battery pack.

Abstract: A traction battery pack venting assembly includes an enclosure, at least one cell stack within the enclosure, a cross-member assembly within the enclosure, and a valve assembly that opens to provide a vent path from the at least one cell stack to a passageway of the cross-member assembly. A method of establishing a vent path within a traction battery pack includes, within a battery pack enclosure, using a valve assembly to block an opening to a passageway provided by a cross-member assembly; and in response to at least one battery cell within the battery pack enclosure venting, opening the valve assembly to permit flow through the opening to the passageway.

Abstract: Multifunctional cross-member beams are provided for use within traction battery packs. An exemplary cross-member beam may include features for interfacing with and supporting various subcomponents (e.g., battery cells, cell tab terminals, bus bars, thermal barriers, etc.) of a cell stack of the traction battery pack. The cross-member beam may further incorporate features for facilitating the venting of battery cell vent byproducts during battery thermal events.

Abstract: An article, such as a battery pack system, includes a battery pack that is comprised of a plurality of battery cells. An external housing covers at least a portion of the battery pack. A silicate-based thermal barrier coating is configured to block heat emitted from the battery pack.

Abstract: A battery housing for a traction battery. The battery housing includes a first housing shell, and a second housing shell which can be connected to the first housing shell, for bounding an interior formed to receive at least one battery module. The first housing shell has a first collar which runs at least partially around the first housing shell. The second housing shell has a second collar which runs at least partially around the second housing shell. The battery housing has at least one connection element having two pressure limbs. The at least one connection element engages around the first collar and the second collar and to clamp by the two pressure limbs of the connection element exerting a normal force on the first collar and on the second collar. The first collar and/or the second collar has at least one first latching means. The connection element has at least one second latching means.

Abstract: A traction battery pack for an electrified vehicle may include a protection bracket for shielding a vent feature of the traction battery pack. An exemplary protection bracket may be made of a polymeric material and is designed to shield the vent feature from debris impingement. The protection bracket may include features such as a mesh venting pattern and a melting point that is lower than the temperature of battery vent byproducts that may be released during battery thermal events of the traction battery pack.

Abstract: Traction battery packs are disclosed that include battery systems. A cell stack/cell matrix of the battery system may be positioned within an enclosure tray of the traction battery pack. A wedge insert may be positioned at an interface between the cell stack/cell matrix and a side wall of the enclosure tray. The side wall may include a draft angle. The wedge insert may be configured to translate the draft angle in order to apply a compressive load in a direction that is substantially normal to the cell stack/cell matrix.

Abstract: A traction battery pack assembly includes, among other things, first and second pieces of an enclosure having an interior area. An attachment rim is disposed at a periphery of the first piece. The attachment rim has a stand-off that includes a platform portion and turned flange. The platform portion extends outward from the interior area in a first direction. The platform portion provides an aperture. The turned flange extends away from the platform portion in a second direction and terminates at an end face. The second direction is transverse to the first direction. The aperture is configured to receive a fastener that clamps the end face against the second piece.

Abstract: A traction battery assembly includes a thermal exchange device of a battery pack, and battery arrays disposed adjacent the thermal exchange device. A phase change material is secured to an area of the thermal exchange device. A method of managing thermal energy within a battery pack includes, among other things, positioning battery arrays against a thermal exchange device, and securing a phase change material to the thermal exchange device. The phase change material is configured to take on thermal energy from at least one of the battery arrays.

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: 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: Manufacturing processes are disclosed for assembling traction battery packs that include battery systems, such as cell-to-pack battery systems. An exemplary assembly method includes inserting one or more cell stacks of the cell-to-pack battery system into a cell-compressing opening of an enclosure tray. The method may involve the use of slider plates that provide sliding surfaces that facilitate the insertion of the cell stacks into the cell compressing opening.