Abstract: A battery pack assembly includes a cell stack having a plurality of battery cells, a thermal barrier adjacent the cell stack, and deflector hoods included within the thermal barrier. Each deflector hood configured to move from a closed position to an open position in response to a flow of vent byproducts against the deflector hood.

Abstract: An traction battery pack assemblies includes enclosure assembly providing an interior area. At least one cell stack having a plurality of battery cell groups disposed along a cell stack axis is within the interior area. The at least one cell stack includes a plurality of dividers disposed along the cell stack axis. Each of the divider assemblies is disposed axially between a first and a second battery cell group within the plurality of battery cell groups. A seal is associated with each of the dividers within the plurality of the dividers. The seal seals an interface between the respective divider and the enclosure assembly. The seal can be a bulb seal.

Abstract: This disclosure details exemplary traction battery pack venting systems for use in electrified vehicles. An exemplary traction battery pack system may include a venting system having one or more vent ducts for expelling battery vent byproducts from a battery pack. The vent ducts may include a thermal barrier configured to block heat emitted by the battery vent byproducts during cell venting events. In some embodiments, the thermal barrier includes a thermal barrier coating. In other embodiments, the thermal barrier includes both a thermal barrier coating and a thermal barrier layer. In still other embodiments, a second thermal barrier may be applied to vehicle components located near the battery pack for improving the thermal barrier properties.

Abstract: Battery thermal barrier foam systems are provided for use within traction battery packs. Exemplary battery thermal barrier foam systems may include one or more foam blocks arranged to fill void spaces within a battery array of a traction battery pack. Each foam block may include a high temperature material system capable of mitigating cell-to-cell and/or array-to-array thermal propagation, increasing thermal insulation between battery cells, absorbing heat, etc.

Abstract: A foam material includes the reaction product of a polyol mixture and an isocyanate mixture and a graphite filler obtained from spent lithium-ion batteries. The graphite filler defines a layered structure and adhesion anchor points.

Abstract: A thermal management system for a traction battery pack includes a cell stack having a plurality of battery cells, and a thermal exchange device adjacent the at least one cell stack. The thermal exchange device has at least one coolant passageway that communicates a coolant, and a plurality of thermal breaks configured to inhibit thermal energy transfer from a first area of the thermal exchange device to a different, second area of the thermal exchange device.

Abstract: A traction battery pack assembly includes an enclosure assembly that provides an interior area, at least one cell stack having a plurality of battery cell groups and a plurality of dividers disposed along a cell stack axis, and a plurality of compressible barriers attached to the enclosure assembly. Each compressible barrier within the plurality of compressible barriers is configured to contact a respective divider within the plurality of dividers.

Abstract: A foam material includes the reaction product of a polyol mixture and an isocyanate mixture and a graphite filler obtained from spent lithium-ion batteries in an amount of ?0.025 wt. % to ?0.5 wt. % such that the graphite filler provides a foam material that has a plane wave absorption coefficient of greater than or equal to about 0.75 at 600 Hz.

Abstract: This disclosure relates to a battery assembly of an electrified vehicle, and in particular to a battery pack with a hinged flap configured to release vent gas. In some aspects, the techniques described herein relate to a battery assembly for an electrified vehicle, including: a battery array including a plurality of battery cells; an enclosure assembly surrounding the battery array; and a frame within the enclosure assembly, wherein the frame includes a flap, wherein the flap includes a perimeter having a first portion along which a first gap is present between the flap and the frame throughout an entirety of a thickness of the frame, and a second portion configured as a hinge of the flap and along which a second gap is present only partially through the thickness, wherein the second gap is formed in a side of the frame facing the plurality of battery cells.

Abstract: Thermal mitigation systems are provided for traction battery packs. An exemplary thermal mitigation system may include a cartridge containing a nitrogen releasing material, and a heating element. The heating element may be activated to cause the nitrogen releasing material to release a nitrogen gas for actively mitigating battery thermal events. Another exemplary thermal mitigation system may include one or more passive release devices that are mounted to a battery array. A nitrogen releasing material may be activated via heat generated within the battery array to release a nitrogen gas from a polymeric encapsulating material of the passive release device to passively mitigate battery thermal events.

Abstract: Battery thermal suppression systems are provided for battery arrays and/or traction battery packs. Exemplary thermal suppression systems may include one or more aerosol devices that are adapted to release potassium (K) radicals when the material temperature reaches a predefined temperature threshold, thereby mitigating the effects of battery thermal events. The aerosol devices may be passive devices that can be implemented at the battery array level, the battery pack level, or both. Each aerosol device may be mounted in relatively close proximity to but without touching the battery cells of the battery array/battery pack.

Abstract: Battery thermal barrier systems are provided for traction battery packs. Exemplary battery thermal barrier systems may include one or more components that include a foam portion and an endothermic aerogel system configured to mitigate the effects of battery thermal events. The components may include bifurcation structures, canopy structures, thermal barrier plates, or combinations thereof.

Abstract: Exemplary thermal barrier systems are provided for traction battery packs. Exemplary battery thermal barrier systems may include one or more thermal barrier structures that are positioned between neighboring groupings of battery cells of a cell bank and/or elsewhere within a battery array of the traction battery pack. The thermal barrier structures may include a foam-insulation-foam multi-layer structure, an insulation-foam-insulation multi-layer structure, or an insulation-foam multi-layer structure. The thermal barrier structures are designed to manage cell-to-cell transfers of heat and electrical energy during battery thermal events.

Abstract: Busbar systems are provided for use within traction battery packs. The busbar systems may include one or more integrated thermal barriers for mitigating the effects of battery thermal events. The thermal barriers may be integrated as part of an outer housing of the busbar system, as part of a fuse area of a busbar of the busbar system, or both.

Abstract: A battery system includes a first battery module, a second battery module, and a thermoresistant spacer disposed between the first battery module and the second battery module. The thermoresistant spacer may be a thermoresistant urethane foam or a silicon pad and may include thermoresistant additives, which may include at least one of melamine resin powder, aerogel particles, and milled oxidized polyacrylonitrile fibers. A flame retardant material may be disposed over at least a surface of the thermoresistant spacer.

Abstract: A battery pack assembly includes a first cell stack having a first side and a second side. The first side is transverse to the second side. A second cell stack is adjacent the first side of first cell stack. A divider has a barrier portion and an attachment portion. The barrier portion is disposed between the first side of the first cell stack and the second cell stack. The attachment portion is secured directly to the second side of the first cell stack.

Abstract: Battery thermal barrier and venting systems are provided for battery arrays. Exemplary battery thermal barrier and venting systems may include one or more endothermic intumescent aerogel sheets that are configured to activate when surrounding battery temperatures exceed a predefined temperature threshold, thereby mitigating cell-to-cell thermal propagation. The endothermic intumescent aerogel sheets may be incorporated as part of thermal barrier structures that are positioned between neighboring battery cells of a cell bank, as part of partition structures that are positioned between adjacent cell banks of a battery array, or both. The battery thermal barrier and venting systems may further include one or more vent ports and vent port covers for venting gases and other effluents from the battery array.

Abstract: A traction battery assembly includes a thermal exchange plate, a battery array disposed on the thermal exchange plate, an enclosure structure supporting the battery array and the thermal exchange plate, and a thermal barrier sandwiched between the thermal exchange plate and the enclosure structure. A method of shielding areas of a traction battery pack from thermal energy includes positioning a thermal barrier between a thermal exchange plate and an enclosure structure. The thermal barrier is configured to block transfer of thermal energy from the thermal exchange plate to the enclosure structure.

Abstract: An article, such as a battery pack system, includes a battery pack that is comprised of a plurality of battery cells. An external housing covers at least a portion of the battery pack. A silicate-based thermal barrier coating is configured to block heat emitted from the battery pack.

Abstract: A method of producing an aerogel-based material includes placing a sol mixture into a cavity of a tool. The sol mixture includes a precursor and a solvent. The cavity of the tool is sealed and the sol mixture is heated under pressure to at least supercritical conditions, thereby creating a flammable gas within the cavity of the tool. The flammable gas within the cavity of the tool is ignited.