Abstract: A traction battery system for a vehicle is provided. The system may include a plurality of battery cells, a thermal plate, and an inlet manifold. The thermal plate may support the battery cells and includes a heat exchange region and two lateral sides defining two planes. The inlet manifold may be positioned downstream of an inlet port and upstream of the heat exchange region. The inlet manifold may define distribution channels throughout the inlet manifold and includes an outlet to the heat exchange region having a cross-sectional area defining a third plane. The two planes and third plane define a region normal to the cross sectional area and the inlet manifold may be positioned such that the inlet port is located outside the region.

Abstract: A vehicle traction battery assembly is provided which may include a support structure, a thermal interface component, and a pressure plate. The support structure may include a center bar arrangement and may be configured to support a thermal plate and battery cell array. The thermal interface component may be disposed between the array and plate. The pressure plate may be on an upper face of the array. The assembly may be configured to exert a force against the pressure plate to compress the thermal interface component between the thermal plate and array. The center bar arrangement may include a center bar extending along the array and may be shaped to define a passageway between the upper face and the center bar. The pressure plate may be at least partially disposed within the passageway.

Abstract: A high voltage battery module comprises a plurality of battery cells stacked in an array. The array is covered on its ends by a pair of opposing end plates, and is covered on its sides by a pair of opposing sidewalls. The sidewalls partially cover upper surfaces of the battery cells. Internal channels provide gaps between the sides of the battery cells and the interior surfaces of the sidewalls. An external channel is vertically spaced from the internal channel and is defined by the exterior surfaces of the sidewalls. Brackets secure the end plates to the sidewalls by at least partially extending into the external channels of the sidewalls.

Abstract: A battery array according to an exemplary aspect of the present disclosure includes, among other things, a rail that supports a battery cell and a tie bracket connected to the rail and configured to limit travel of the rail.

Abstract: A high voltage battery module comprises a plurality of battery cells stacked in an array. The array is covered on its ends by a pair of opposing end plates, and is covered on its sides by a pair of opposing sidewalls. The sidewalls partially cover upper surfaces of the battery cells. Internal channels provide gaps between the sides of the battery cells and the interior surfaces of the sidewalls. An external channel is vertically spaced from the internal channel and is defined by the exterior surfaces of the sidewalls. Brackets secure the end plates to the sidewalls by at least partially extending into the external channels of the sidewalls.

Abstract: A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells and a thermally conductive film wrapped around each of the plurality of battery cells. Each thermally conductive film is contiguous with six sides of each of the plurality of battery cells.

Abstract: A traction battery includes a first thermal plate disposed within a case, and cells disposed on the first thermal plate. A bracket arrangement is disposed within the case. The bracket arrangement includes a second thermal plate spaced apart from the first thermal plate, and a leg defining at least a portion of a fluid path connecting flow channels of the first and second thermal plates. An electronic component is disposed on the second thermal plate.

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: A vehicle traction battery assembly includes at least one battery cell array, and an electronics assembly configured to manage power flow of the battery assembly. The vehicle traction battery assembly also includes a thermal plate defining a first portion in contact with the at least one array and a second portion in contact with the electronics assembly. During power flow, both of the at least one array and the electronics assembly exchange heat with the thermal plate.

Abstract: A battery array according to an exemplary aspect of the present disclosure includes, among other things, a rail that supports a battery cell and a tie bracket connected to the rail and configured to limit travel of the rail.

Abstract: A vehicle traction battery assembly is provided which may include a support structure, a thermal interface component, and a pressure plate. The support structure may include a center bar arrangement and may be configured to support a thermal plate and battery cell array. The thermal interface component may be disposed between the array and plate. The pressure plate may be on an upper face of the array. The assembly may be configured to exert a force against the pressure plate to compress the thermal interface component between the thermal plate and array. The center bar arrangement may include a center bar extending along the array and may be shaped to define a passageway between the upper face and the center bar. The pressure plate may be at least partially disposed within the passageway.

Abstract: A high voltage battery module comprises a plurality of battery cells stacked in an array. The array is covered on its ends by a pair of opposing end plates, and is covered on its sides by a pair of opposing sidewalls. The sidewalls partially cover upper surfaces of the battery cells. Internal channels provide gaps between the sides of the battery cells and the interior surfaces of the sidewalls. An external channel is vertically spaced from the internal channel and is defined by the exterior surfaces of the sidewalls. Brackets secure the end plates to the sidewalls by at least partially extending into the external channels of the sidewalls.

Abstract: A vehicle traction battery assembly is provided which may include a housing, a battery system supported within the housing, and a connector electrically connected with the system and extending through and away from the recessed face into a region normal to the recessed face and adjacent to the ledge such that the ledge limits travel of objects into the region impacting the lateral end. The lateral end may have a step configuration defined by the ledge and the recessed face. The housing may also include a middle face extending between the ledge face and recessed face, opposing side faces, and a lower face. The connector may be a battery control interface connector, an accessory connector, or a high-voltage connector.

Abstract: A battery pack for a vehicle may include a cell array defining an upper surface and a housing defining a raised portion extending along and above a length of the array such that the raised portion and upper surface define a vent manifold therebetween which may be configured to collect gases generated by the array. The housing may define a discharge opening configured to allow gases to exit the manifold. A pair of end plates may be disposed at opposing ends of the array. One of the end plates may define a pass through portion in at least partial registration with the discharge opening. An outlet tube may be configured to facilitate fluid communication between the vent manifold and exterior of the vehicle. The battery pack may also include spacers located between upper edges of adjacent cells and may be configured to prevent cooling gases from entering the vent manifold.

Abstract: A battery pack of the type that may be used in an electrically-powered vehicle comprises first and second arrays of cells disposed adjacent one another, and a housing enclosing the two arrays. The housing defines a cooling chamber surrounding heat transfer surfaces of the cells, a first manifold sealed from the cooling chamber and collecting gasses generated by the first array, and a second manifold sealed from the cooling chamber and collecting gasses generated by the second array. A tunnel connects the first and the second manifolds to allow passage of any collected gasses from the first manifold into the second manifold, and a discharge opening in the second manifold allows the collected gasses to escape from the housing. An electrically conductive bridge bar extends through the tunnel and connects the first array with the second array.

Abstract: A battery assembly may include an array of battery cells each having upper and lower ends, a face extending therebetween and partially defining an exterior of the array, and terminals extending from the upper end. The battery assembly may also include an exo-support structure including a plurality of retainer segments configured to support the upper and lower ends and a thermal plate defining one or more channels extending along the exterior of the array. The thermal plate may be arranged to thermally communicate with the battery cells via the faces. The exo-support structure may further include another thermal plate defining one or more channels extending along another exterior of the array which are arranged to thermally communicate with the cells. The battery assembly may include at least one cell separator made of a thermally conductive material which is located between two adjacent cells.

Abstract: A traction battery system for a vehicle is provided. The system may include a plurality of battery cells, a thermal plate, and an inlet manifold. The thermal plate may support the battery cells and includes a heat exchange region and two lateral sides defining two planes. The inlet manifold may be positioned downstream of an inlet port and upstream of the heat exchange region. The inlet manifold may define distribution channels throughout the inlet manifold and includes an outlet to the heat exchange region having a cross-sectional area defining a third plane. The two planes and third plane define a region normal to the cross sectional area and the inlet manifold may be positioned such that the inlet port is located outside the region.

Abstract: An example battery pack separator includes a spacer section and a vent section. The spacer section has a portion that is operative to fit between a first battery cell and a second battery cell along an axis. The portion has a perimeter. A vent section has an aperture that extends away from the axis outside the perimeter.

Abstract: An example battery pack spacer includes a base and at least one rib extending laterally from the base. The rib is configured to turn flow of a coolant through a battery pack.

Abstract: A traction battery includes a housing that has a tray and a cover, and a plurality of battery components supported by the tray and enclosed by the cover. A service disconnect base is disposed within the housing and is electrically connected with the components by a circuit. The housing includes an access panel with a service disconnect plug attached to the panel. The access panel is movable between open and closed positions. The service disconnect plug connects circuitry within the service disconnect base when the panel is in the closed position. The service disconnect plug is disconnected with the service disconnect base when the panel is in the open position to open the circuit.