Abstract: A battery array frame may include a frame body extending along a longitudinal axis and including a top frame rail, a bottom frame rail, and frame arms that connect between the top frame rail and the bottom frame rail. An insert extends inside the frame body for increasing the stiffness of the frame body.

Abstract: A battery pack includes an array frame having a fastener housing, a mounting insert positioned within the fastener housing, and a column bolt extending through the mounting insert. The mounting insert may be secured to a battery pack enclosure structure using one or more fasteners.

Abstract: An exemplary method of securing portions of a battery pack includes, among other things, slidably engaging a portion of a battery cell frame within a channel of an extrusion, and securing the extrusion to a support to secure the battery cell frame.

Abstract: An exemplary battery assembly includes a first terminal holder, and a terminal at least partially surrounded by the first terminal holder. The first terminal holder includes a locating feature to position the first terminal holder relative to a second terminal holder.

Abstract: An exemplary support assembly for a battery array includes, among other things, a frame and an insert secured to the frame. The insert is configured to hold at least one battery cell within the frame. The frame is made of a first material and the insert is made of a second material that is softer than the first material. An exemplary method of securing a battery cell within a traction battery pack of an electrified vehicle includes, among other things, compressing an insert against the at least one battery cell. The insert is secured to a frame made of a first material. The insert is made of a second material that is softer than the first material.

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.

Abstract: A battery pack includes a grouping of battery cells and a plurality of array frames for retaining the grouping of battery cells. Each of the plurality of array frames includes a ratchet feature. A column bolt includes a raised surface configured to mate with the ratchet feature of each of the plurality of array frames to secure the plurality of array frames together.

Abstract: A battery pack includes a support structure, an array frame including a fastener housing, and a fastener received through the fastener housing for mounting the array frame to the support structure. The array frame may be mounted to the support structure using a top-down approach that includes inserting a fastener through a fastener housing of the array frame.

Abstract: This disclosure details battery assemblies for use within electrified vehicle battery packs. An exemplary battery assembly includes a grouping of battery cells and an array plate assembly contacting a portion of the battery assembly. The array plate assembly may embody a split panel design that includes an outer panel and an inner panel that are arranged to nest together. One or both of the outer panel and the inner panel may include an embossing pattern. Among various other advantages, the split panel design increases the stiffness of the array plate assembly without significantly increasing the overall package depth of the array plate assembly or the battery assembly.

Abstract: An exemplary battery assembly includes, among other things, a frame, and a thermal fin extending through an aperture in the frame. The thermal fin is configured to transfer thermal energy between a battery cell and a thermal exchange plate. An exemplary method of thermal energy transfer within a battery pack includes, among other things, transferring thermal energy between at least one battery cell and a thermal exchange plate using a thermal fin that extends through an aperture in a frame.

Abstract: An exemplary support assembly includes, among other things, a hoop bracket coupling a battery pack to a vehicle body structure, and a tuned bracket within an open area of the hoop bracket. The tuned bracket is configured to control a collapse of the hoop bracket in response to a load above a threshold level to reduce a transfer of the load to the battery pack. An exemplary supporting method includes coupling a battery pack to a vehicle body structure using a hoop bracket disposed alongside the battery pack. The hoop bracket includes an open area that receives a tuned bracket. The tuned bracket is configured to control a deformation of the hoop bracket in response to a load above a threshold level to reduce a transfer of the load to the battery pack.

Abstract: An exemplary battery assembly includes, among other things, a thermal fin, a frame holding the thermal fin, and a stand-off of the frame configured to limit relative movement of the thermal fin toward a thermal exchange plate. An exemplary thermal fin positioning method, includes limiting relative movement of a thermal fin toward a thermal exchange plate using a stand-off disposed upon a battery cell assembly frame.

Abstract: A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.

Abstract: A battery pack includes a support structure, an array frame mounted relative to the support structure, and a thermal fin held within the array frame and grounded to the support structure. The thermal fin may include a grounding extension that is grounded to the support structure.

Abstract: A battery assembly includes a grouping of battery cells and an array plate assembly contacting at least one cell of the grouping of battery cells. The array plate assembly including a spring plate adapted to exert a compressive spring force against the at least one cell. The compressive spring force may be based on a dimensional profile of the grouping of battery cells.

Abstract: A battery pack includes a support structure, an array frame including a fastener housing, and a fastener received through the fastener housing for mounting the array frame to the support structure. The array frame may be mounted to the support structure using a top-down approach that includes inserting a fastener through a fastener housing of the array frame.

Abstract: A battery pack retention assembly includes, among other things, a conforming bracket that secures a battery array within a battery pack. The conforming bracket includes platforms that flexes as the conforming bracket is secured. The flexing facilitates aligning an area of the conforming bracket with a thermal exchange plate. A battery pack retention method includes, among other things, flexing a conforming bracket to reduce a gap between the battery array and a thermal exchange plate. The flexing occurs when securing a battery array to within a battery pack.

Abstract: A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.

Abstract: A battery module according to an exemplary aspect of the present disclosure includes, among other things, an array of battery cells, a compression structure including a first wall and a second wall, at least one conduit configured to convey fluid adjacent the array, and a tension member connected to the first wall and the second wall. The tension member is adjacent the at least one conduit. This disclosure also relates to an electrified vehicle and a method.

Abstract: A battery array frame may include a frame body extending along a longitudinal axis and including a top frame rail, a bottom frame rail, and frame arms that connect between the top frame rail and the bottom frame rail. An insert extends inside the frame body for increasing the stiffness of the frame body.