Abstract: A motor vehicle according to an exemplary aspect of the present disclosure includes, among other things, a frame including a rail and an electrical distribution system routed at least partially through the rail. A method is also disclosed.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a battery system and an expandable polymer foam enclosure that substantially encapsulates the battery system. An expandable polymer foam may be introduced into a mold, expand, and then cure around to battery system to form the enclosure.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a polymer-based enclosure assembly having features for thermally managing internal components of the battery pack. In some embodiments, the enclosure assembly may include molded-in fluid channels or molded-in tubing for establishing a cooling circuit of the battery pack. In other embodiments, the enclosure assembly may include molded-in channels that receive tubing for establishing a cooling circuit of the battery pack.

Abstract: An exemplary retention assembly includes a plurality of battery cells, a heat exchange structure, and a strap that pulls together the heat exchange structure and the plurality of battery cells.

Abstract: An exemplary attachment method includes, among other things, to electrically couple a first battery cell to a busbar, joining a terminal of the first battery cell to the busbar with a first weld. The method further includes, to electrically couple a second battery cell to the busbar, joining a terminal of the second battery cell to the terminal of the first battery cell with a second weld. An exemplary attachment assembly includes, among other things, a busbar, a first terminal of a first battery cell, and a second terminal of a second battery cell. The first terminal is electrically coupled to the busbar with a first weld that joins the first terminal to the busbar. The second terminal is electrically coupled to the busbar with a second weld that joins the second terminal to the first terminal.

Abstract: A battery array frame according to an exemplary aspect of the present disclosure includes, among other things, a frame body, and a thermal fin including a body embedded in the frame body and a leg that extends outside of the frame body. The thermal fin is flexible between a first position in which the leg is spaced farther from a surface of the frame body and a second position in which the leg is spaced closer to the surface of the frame body.

Abstract: Electrified vehicles such as hybrid electric vehicles (HEV's), plug-in hybrid electric vehicles (PHEV's), battery electric vehicles (BEV's), or fuel cell vehicles differ from conventional motor vehicles in that they are powered by one or more electric machines (i.e., electric motors and/or generators) instead of or in addition to an internal combustion engine. High voltage current for powering these types of electric machines is typically supplied by a high voltage traction battery system having one or more battery cells that store energy.

Abstract: This disclosure details exemplary insulating flexible membranes for use with vehicle high voltage modules. The high voltage modules may include any module that is adapted for supporting electric propulsion within the vehicle. The insulating flexible membranes may be attached to an exterior of a housing, to an interior of the housing, or may be disposed about a high voltage component housed inside the module. The insulating flexible membranes of this disclosure are configured to distort to prevent access to damaged high voltage components of the high voltage modules.

Abstract: An exemplary battery pack assembly includes an endplate with a first side region and a second side region opposite the first side region, a first connector in the first side region, and a second connector in the second side region. The first and second connectors each provide a connection point to secure the endplate to a support when a respective one of the first or second side regions is positioned proximate the support.

Abstract: A battery array frame according to an exemplary aspect of the present disclosure includes, among other things, a frame body, and a thermal fin including a body embedded in the frame body and a leg that extends outside of the frame body. The thermal fin is flexible between a first position in which the leg is spaced farther from a surface of the frame body and a second position in which the leg is spaced closer to the surface of the frame body.

Abstract: A hybrid energy storage and delivery device includes a plastic enclosure that establishes a first sealed chamber and a second sealed chamber. The first sealed chamber is configured as a fuel tank for storing a liquid fuel and the second sealed chamber is configured as a battery pack for storing electrical energy. Thus, the fuel tank and battery pack may be integrated together within a single enclosure in order to improve vehicle packaging efficiencies.

Abstract: An exemplary attachment method includes, among other things, to electrically couple a first battery cell to a busbar, joining a terminal of the first battery cell to the busbar with a first weld. The method further includes, to electrically couple a second battery cell to the busbar, joining a terminal of the second battery cell to the terminal of the first battery cell with a second weld. An exemplary attachment assembly includes, among other things, a busbar, a first terminal of a first battery cell, and a second terminal of a second battery cell. The first terminal is electrically coupled to the busbar with a first weld that joins the first terminal to the busbar. The second terminal is electrically coupled to the busbar with a second weld that joins the second terminal to the first terminal.

Abstract: A method according to an exemplary aspect of the present disclosure includes, among other things, compressing a cell stack, which itself includes at least one battery cell and a support plate spaced-apart from an upper surface of the cell(s). The method further includes inserting the cell stack into a pocket of a structural assembly by applying a force to the support plate. A battery assembly is also disclosed.

Abstract: An electrical storage device heater system according to an exemplary aspect of the present disclosure includes, among other things, an electrical storage device, a heater configured to regulate a temperature of the electrical storage device and a controller configured to actuate the heater using power sourced from a location separate from the electrical storage device.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include an enclosure assembly that houses one or more battery internal components (e.g., battery arrays, battery electronic components, or both). A tear-away service panel may be positioned within a wall of the enclosure assembly. The service panel may be removed from the enclosure assembly to access one of the battery internal components requiring service and may be subsequently replaced with a replacement service panel. The replacement service panel may be part of a battery pack resealing kit.

Abstract: A battery assembly includes a cell stack and an array structure. At least one of the cell stack and the array structure includes a biased profile configured to bias the cell stack and a portion of the array structure together.

Abstract: A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, an enclosure assembly defining an interior and a variable volume device integrated into a wall of the enclosure assembly and configured to modify a volume of the interior.

Abstract: An exemplary battery assembly includes an endplate of a battery array, and an enclosure wall secured directly to the endplate from outside an open area of a battery pack enclosure. An exemplary method of securing a battery array includes positioning a battery array within an open area of an enclosure and, from a position outside the open area, securing an endplate of a battery array directly to a wall of a battery pack enclosure.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack assembly process may include supporting one or more components, such as a heat exchanger plate, of the battery pack against deflection during the assembly process. Supporting the heat exchanger plate to keep the plate relatively flat during the battery pack assembly process improves the flow distribution of a thermal interface material (TIM), thereby achieving improved TIM coverage and improved heat transfer between battery cells and the heat exchanger plate of the battery pack.

Abstract: An example battery pack retention system includes, among other things, a retention assembly that transitions from a disengaged to an engaged position in response to movement of a portion of a battery pack enclosure relative to a battery array housed within the battery pack enclosure. An example securing method includes, among other things, moving a portion of a battery pack enclosure relative to a battery array that is housed within the battery pack enclosure to transition a retention assembly from a disengaged to an engaged position.