Abstract: Structural cross-member assemblies are provided for use within traction battery packs. An exemplary traction battery pack may include a cell stack including a plurality of battery cells arranged between a first cross-member assembly and a second cross-member assembly. Each cross-member assembly of the cell stack may include a ladder frame and one or more reinforcement beams mounted to the ladder frame. Each reinforcement beam may be a pultrusion. The pultrusion may be configured to enable the cross-member assembly to react against both tensile loads and compressive loads that act on the cell stack.

Abstract: Multi-functional cross-member assemblies are provided for traction battery packs. An exemplary cross-member assembly may function as both a structural member for supporting one or more cell stacks and further as a “cold plate” for thermally managing the one or more cell stacks. In some implementations, the cross-member assembly may include structural beam members (e.g., pultrusions) and a heat exchanger portion that includes an internal coolant circuit.

Abstract: Banding straps and associated methods may be used for assembling a cell stack of a traction battery pack. One more banding straps may be arranged about the cell stack for temporarily or permanently applying and maintaining compression across the cell stack. In an exemplary method, a banding strap may be arranged within a compression fixture before positioning a cell stack within the compression fixture and applying a compressive force across a cell stack axis of the cell stack. Free end portions of the banding strap may be connected to maintain the compressive force across the cell stack axis.

Abstract: Structural cross-member assemblies are provided for traction battery packs. An exemplary cross-member assembly may include a cross-member beam having a beam body and at least one reinforcement section that provides structural integrity to the beam body. The reinforcement section may be a pultrusion and may embody various cross-sectional shapes. The cross-member beam may be positioned adjacent to an additional cross-member beam to establish the cross-member assembly disposed between adjacent cell stacks of the traction battery pack.

Abstract: Electrical connection systems are provided for electrically connecting cell stacks of a traction battery pack. Exemplary electrical connections systems may include a first high voltage terminal of a first cell stack and a second high voltage terminal of a second cell stack. The first high voltage terminal may be mounted to a first cross-member beam of the first cell stack, and the second high voltage terminal may be mounted to a second cross-member beam of the second cell stack. The first high voltage terminal may be arranged and coupled to the second high voltage terminal to electrically connect the first cell stack and the second cell stack.

Abstract: Bus bar routing configurations are provided for traction battery packs. Exemplary routing configurations may position the bus bar over top of one or more cells stacks of the traction battery pack. A structural cross-member beam of each cell stack may include a notch for accommodating the bus bar. The bus bar may therefore be conveniently nested within the cross-member beam without increasing the vertical or “z-axis” footprint of the traction battery pack.