Abstract: A traction battery assembly according to an exemplary aspect of the present disclosure includes a lower tier of battery arrays, an upper tier of battery arrays, and a support structure disposed between the lower tier and the upper tier. The lower tier is suspended from a downwardly facing side of the support structure. The upper tier is disposed atop an upwardly facing side of the support structure.

Abstract: A service tool assembly according to an exemplary aspect of the present disclosure includes, among other things, a service tool that extends through an access hole in a floor of an electrified vehicle and is adapted to engage a threaded hole of a battery pack. The service tool is rotatable to translate the battery pack relative to the electrified vehicle.

Abstract: A battery pack assembly includes a first battery array, a second battery array adjacent the first battery array, a thermal control assembly that includes a thermal blanket spanning across the first battery array and the second battery array, and a partitioning region of the thermal control assembly. The partitioning region extends to a position between the first battery array and the second battery array. The partitioning region includes a foam core.

Abstract: A battery pack assembly includes a first battery array, a second battery array adjacent the first battery array, and a thermal barrier assembly that blocks transfer of thermal energy between the first battery array and the second battery array. The thermal barrier assembly having a sheet of material that is folded to provide a plurality of layers.

Abstract: A battery pack assembly includes battery cells, a first endplate adjacent a first end of the battery cells, a second endplate adjacent an opposite, second end of the battery cells, and a tension member. The first and second endplates are each slidably coupled to the tension member. A compressible member is disposed between the first endplate and a section of an enclosure. The compressible member is configured to compress in response to the battery cells expanding and moving the first endplate toward the section of the enclosure.

Abstract: A battery pack assembly includes battery cells, a thermal barrier adjacent the battery cells, and at least one scored region of the thermal barrier. The scored region is configured to rupture to provide a vent flap that opens to establish a vent path for gas expelled from at least one of the battery cells.

Abstract: Battery array designs for electrified vehicle battery packs may include a thermal interface material disposed between battery cells of the array and both a top plate and a bottom plate of an array support structure. The battery array may therefore be configured to transfer heat through the top, bottom, or both. The battery array may further include a mounting flange located an equal distance from both the top plate and the bottom plate along a side plate of the array support structure. The battery array therefore provides a symmetrical design that simplifies assembly.

Abstract: Exemplary bus bar assemblies may be used to electrically couple adjacent components of electrified vehicle traction battery packs, for example. An exemplary bus bar assembly may include a bus bar and a cover disposed about portions of the bus bar. The bus bar may include a single combined electrical interface section and multiple component electrical interface sections for connecting multiple traction battery pack electrical components in parallel configurations.

Abstract: A traction battery assembly includes battery cells of a battery array, and switches of the battery array. The switches are transitionable between a first configuration and a second configuration. When the switches are in the first configuration, the battery cells of the array are partitioned into a first number of groups of battery cells in parallel with each other. When the switches are in the second configuration, the battery cells of the array are partitioned into a different, second number of groups of battery cells in parallel with each other.

Abstract: A traction battery assembly includes, among other things, an array sense lead header of a battery array, a plurality of sense leads extending from the array sense lead header to areas of the battery array, and a battery pack module having a module connector. The battery pack module is configured to move relative to the battery array from a disengaged position where the module connector the array sense lead header are disengaged to an engaged position where the module connector and the array sense lead header are engaged.

Abstract: A traction battery assembly according to an exemplary aspect of the present disclosure includes a lower tier of battery arrays, an upper tier of battery arrays, and a support structure disposed between the lower tier and the upper tier. The lower tier is suspended from a downwardly facing side of the support structure. The upper tier is disposed atop an upwardly facing side of the support structure.

Abstract: This disclosure relates to a battery for an electrified vehicle and a corresponding method. In particular, the battery and method accommodate for variable cell thickness. An example method of this disclosure includes inserting a separator between a first battery cell and a second battery cell. The separator has a thickness based on a thickness of the first battery cell and the second battery cell. This disclosure has a number of benefits. Among them, the method may be used to provide a battery array with a desired overall length despite differences in individual cell thickness. In turn, this leads to improved battery performance and lifespan.