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: 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 assembly includes an extrusion providing a channel that receives a portion of a battery cell frame. The extrusion is securable to a support to secure the battery cell frame relative to the support.

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 fastener assembly includes a stud and a nut. The stud has a proximal end and a distal end with a body therebetween. The stud also has a central axis extending from the proximal end to the distal end. The proximal end has a flange for coupling to a surface. The body has a cavity opening to an orifice at the distal end. The nut is retained within the cavity. Rotation of the nut about the central axis is inhibited.

Abstract: A vehicle underbody includes a tray structure, a battery pack having a plurality of footers and a bracket; and an enclosure surrounding the battery pack. The bracket has a wall attached to the enclosure, a ledge attached to the footers, and a stepped deformation region between the wall and ledge. The stepped deformation region deforms in response to impact to absorb energy associated with the impact.

Abstract: A battery cell separator includes a top surface and a bottom surface. A body extends between the top surface and the bottom surface and includes a first contoured surface on a first side of the body and a second contoured surface on a second side. The first contoured surface and the second contoured surface converging between the top surface and a center of the body and diverging between the center and the bottom surface.

Abstract: A bus bar assembly according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells and a bus bar assembly that electrically connects the plurality of battery cells. The bus bar assembly includes a flexible cable, a voltage sense lead connected to the flexible cable, and a bus bar connected to the voltage sense lead.

Abstract: A battery cell separator according to an exemplary aspect of the present disclosure includes, among other things, a top surface and a bottom surface. A body extends between the top surface and the bottom surface and includes a first contoured surface on a first side of the body and a second contoured surface on a second side. The first contoured surface and the second contoured surface converging between the top surface and a center of the body and diverging between the center and the bottom surface.

Abstract: A vehicle including a pair of spaced apart battery cell arrays, a pair of sub-structures configured to retain the arrays, and a thermal plate assembly disposed between the arrays is provided. Each of the sub-structures may include opposing endplates and opposing upper and lower sidewalls secured to the endplates and each having a flange extending toward and overlapping with the respective flange of the other sub-structure to join the sub-structures without mechanical fastening. The thermal plate assembly may be disposed between the overlapping flanges and the arrays to form a sandwich formation. The thermal plate assembly may include at least one thermal interface component disposed on a side of a thermal plate, and in contact with a portion of at least one of the battery cell arrays.

Abstract: A battery assembly includes a plurality of battery cells and a support structure positioned about the plurality of battery cells. The support structure includes at least one sidewall and the at least one sidewall includes a first flange that extends adjacent a top surface of each of the plurality of battery cells and a second flange that extends beyond a bottom surface of each of the plurality of battery cells.

Abstract: A battery stack is provided having lower and upper battery tiers each formed of at least two battery cell arrays. A pair of brackets are provided for connecting the lower arrays along a top surface of the lower tier and connecting the upper arrays to a bottom surface of the upper tier. The lower and upper battery tiers are secured together by the brackets without hardware mounted to an exterior surface of the stack.

Abstract: A vehicle underbody includes a tray structure, a battery pack having a plurality of footers and a bracket; and an enclosure surrounding the battery pack. The bracket has a wall attached to the enclosure, a ledge attached to the footers, and a stepped deformation region between the wall and ledge. The stepped deformation region deforms in response to impact to absorb energy associated with the impact.

Abstract: An exemplary battery pack heat exchanger includes a wall of an enclosure, and a heat exchanger lid held against the wall to provide a chamber that receives a fluid to exchange thermal energy with a battery array that is outside of the chamber. An exemplary method of managing battery pack thermal energy includes moving a fluid through a chamber within an enclosure wall of a battery pack to adjust thermal energy levels of the battery pack.

Abstract: An exemplary electrified vehicle assembly includes a sensor lead, and a busbar having a protrusion that secures the sensor lead to electrically connect the sensor lead with the busbar. A method of holding a sensor lead includes securing a busbar to at least one terminal of a battery cell, and securing a sensor lead to the busbar using a protrusion of the busbar.

Abstract: A traction battery assembly for a vehicle includes an array of cells stacked on a tray. The array of cells defines opposing longitudinal sides and opposing lateral sides. First and second L-shaped components are attached to the tray. Each of the components includes an end wall and a sidewall that are integrally formed to define a substantially 90° corner. The first and second components are attached together such that each of the sidewalls is disposed adjacent one of the longitudinal sides and each of the end walls is disposed adjacent one of the lateral sides to form a housing around the tray that has an open top and an open bottom.

Abstract: A battery stack is provided having lower and upper battery tiers each formed of at least two battery cell arrays. A pair of brackets are provided for connecting the lower arrays along a top surface of the lower tier and connecting the upper arrays to a bottom surface of the upper tier. The lower and upper battery tiers are secured together by the brackets without hardware mounted to an exterior surface of the stack.

Abstract: A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells and a support structure positioned about the plurality of battery cells. The support structure includes at least one sidewall and the at least one sidewall includes a first flange that extends adjacent a top surface of each of the plurality of battery cells and a second flange that extends beyond a bottom surface of each of the plurality of battery cells.

Abstract: An exemplary method of securing a battery array includes attaching a twist-lock to a case, and securing a battery array to the case by rotating the twist-lock from a first position to a second position. Another exemplary method of securing a battery array includes securing a twist-lock to a case, and rotating the twist-lock from a first position to a second position where a portion of a battery array is clamped between the twist-lock and the case.

Abstract: A two-part fastener for an assembly having a sealed joint formed by at least two flanges or sealing surfaces. A first flange defines a first opening, a second flange defines a second opening with a seal being disposed between the first and second flanges. The flanges and seal are secured together with a bolt and a receiver that defines a threaded hole for receiving the bolt. The receiver includes an end face engaging the first flange and a shoulder engaging the second flange. The spacing between the end face and the shoulder defines a gap for the seal. The shoulder of the receiver may include a weld bead that is welded to the second flange. In one embodiment, three flanges are assembled together with a seal between each flange.