Abstract: A traction battery pack operating method includes charging a traction battery pack of an electrified vehicle. The charging includes charging a first subpack of battery cells together with a second subpack of battery cells. The method can discharge the first subpack separately from the second subpack. The method can include during the discharging, maintaining at least one switch in an open state to electrically isolate the first subpack from the second subpack.

Abstract: A traction battery assembly includes a plurality of battery cells disposed along an array axis, a rounded endplate at an axial end of the plurality of battery cells, and a wrap spanning the rounded endplate. A method of securing a battery array includes positioning a plurality of battery cells between along an array axis between a first rounded endplate and a second rounded endplate, and compressing the plurality of battery cells between the first and second rounded endplates by winding a wrap around the first rounded endplate, the plurality of battery cells, and the second rounded endplate.

Abstract: A battery assembly includes a base including a first locking feature, a lid including a second locking feature, and a metal joint fusing the first locking feature to the second locking feature. The metal joint is configured to melt to disconnect the first locking feature from the second locking feature.

Abstract: A battery housing assembly for housing battery components of an electric vehicle includes a battery tray, a lid, and a sealant. The battery tray includes a channel located outwardly relative to the battery components. The lid is secured to the battery tray and includes an end portion disposed within the channel. The lid further includes at least one alignment feature configured to align the lid and the battery tray. The sealant is disposed within a portion of the channel of the battery tray and is configured to secure the battery tray and the lid to each other. The sealant is further configured to seal an internal cavity of the battery housing assembly.

Abstract: An electrochemical assembly is comprised of dry electrochemical powder layers (e.g., anode layer, separator layer, cathode layer, and/or current collector layer) that are substantially free of solvent and/or binder. The electrochemical assembly is produced by directly disposing (e.g., printing/spraying) dry powder layers into a non-conductive frame.

Abstract: A system for recycling a component of a battery assembly includes a removal tool and a cover of the battery assembly. The cover includes a component removal zone configured to be removable from the cover by the removal tool to expose the component and a locator identifying the component removal zone for removal by the removal tool.

Abstract: A battery assembly includes a base including a first locking feature, a lid including a second locking feature, and a metal joint fusing the first locking feature to the second locking feature. The metal joint is configured to melt to disconnect the first locking feature from the second locking feature.

Abstract: Various methods of making low-tortuosity electrodes are disclosed. In some embodiments, the low-tortuosity electrodes have a tortuosity of less than 2.0 or 1.4 and include battery-active material and solid electrolyte with the solid electrolyte having channels therein that are vertically aligned. A solid-state lithium-ion battery electrode is also disclosed.

Abstract: A wireless cell array tracker includes a daisy chain connecter and processor each supported on a circuit substrate. The circuit substrate is attached to a battery array. The daisy chain connector physically interfaces with a battery sensing module of the battery array. The processor retrieves data from the battery sensing module via the daisy chain connector, and commands wireless transmission of the data.

Abstract: A battery housing assembly for housing battery components of an electric vehicle includes a battery tray, a lid, and a sealant. The battery tray includes a channel located outwardly relative to the battery components. The lid is secured to the battery tray and includes an end portion disposed within the channel. The lid further includes at least one alignment feature configured to align the lid and the battery tray. The sealant is disposed within a portion of the channel of the battery tray and is configured to secure the battery tray and the lid to each other. The sealant is further configured to seal an internal cavity of the battery housing assembly.

Abstract: A traction battery cell assembly including a battery cell and a cell case is provided. The cell case defines a cavity sized for receiving the battery cell and includes an inner wall, an outer wall, and a plurality of support chambers disposed between the inner wall and the outer wall. Each of the support chambers defines a polygon having multiple sides. The sides are arranged with one another to define an agent cavity to house neutralizing agent. The plurality of support chambers is arranged with the inner wall and the outer wall such that an impact to one of the walls causes a puncture to one of the sides of the support chambers releasing the neutralizing agent. Each of the support chambers may include five or more sides and adjacent sides may define an angle therebetween greater than ninety degrees.

Abstract: A wireless cell array tracker includes a daisy chain connecter and processor each supported on a circuit substrate. The circuit substrate is attached to a battery array. The daisy chain connector physically interfaces with a battery sensing module of the battery array. The processor retrieves data from the battery sensing module via the daisy chain connector, and commands wireless transmission of the data.

Abstract: This disclosure details exemplary home energy storage systems capable of storing electricity locally for later consumption, such as for charging an electrified vehicle, supporting various home energy needs, and supporting alternative energy storage/power source functionality. An exemplary home energy storage system may include a stationary unit, one or more modular units removably connectable to the stationary unit, and a rack mounting and handcart transportation system configured to mount, detach, and transport the modular unit relative to the stationary unit. Once undocked from the stationary unit, the modular unit(s) may be utilized as a portable power source for powering one or more electrical loads. This disclosure further describes various interconnected functionalities (e.g., electrical and wireless communication of state of uses) between the stationary unit and the modular unit of home energy storage systems and between the modular unit and various satellite equipment associated with the modular unit.

Abstract: A vehicle on-board charging assembly includes at least one power electronics module and a coolant channel in thermal contact with the at least one power electronics module. The charging assembly also includes a first reactive portion along a wall of the coolant channel defining a first reactive property and a second reactive portion along the wall of the coolant channel defining a second reactive property. The charging assembly further includes a plurality of emitters arranged to activate the first and second reactive portions. The charging assembly also further includes a controller programmed to sequentially activate the emitters to cause peristaltic pumping of coolant through the coolant channel.

Abstract: A method and system for an electric vehicle include a controller and a battery cooling system. The controller automatically detects when the vehicle is being driven to a charging station. The controller controls the battery cooling system to pre-cool a traction battery of the vehicle as the vehicle is being driven to the charging station so that the traction battery is cooled to a target temperature upon the vehicle reaching the charging station. The battery cooling system includes a phase change material (PCM) surrounding at least a portion of the traction battery. The traction battery is pre-cooled by circulating refrigerant coolant to the PCM to cool the PCM and thereby pre-cool the traction battery.

Abstract: A battery pack includes a pouch cell having electrode tabs extending therefrom, each of the tabs defining perforations, a bus bar in contact with the tabs, and respective agglomerations of mechanically bound solid metal particles each filling one of the perforations to mechanically bind and electrically connect the tabs to the bus bar.

Abstract: A lithium ion pouch battery cell includes a rigid frame forming a skeleton of the cell and defining an aperture, an anode, a separator, and a cathode disposed within the aperture. The anode and cathode each include a current collector with an exposed tab portion, and a pair of terminals, integrated into the frame, each having an exterior portion and an interior portion bonded to one of the current collectors.

Abstract: A vehicle on-board charging assembly includes at least one power electronics module and a coolant channel in thermal contact with the at least one power electronics module. The charging assembly also includes a first reactive portion along a wall of the coolant channel defining a first reactive property and a second reactive portion along the wall of the coolant channel defining a second reactive property. The charging assembly further includes a plurality of emitters arranged to activate the first and second reactive portions. The charging assembly also further includes a controller programmed to sequentially activate the emitters to cause peristaltic pumping of coolant through the coolant channel.

Abstract: A method and system for an electric vehicle include a controller and a battery cooling system. The controller automatically detects when the vehicle is being driven to a charging station. The controller controls the battery cooling system to pre-cool a traction battery of the vehicle as the vehicle is being driven to the charging station so that the traction battery is cooled to a target temperature upon the vehicle reaching the charging station. The battery cooling system includes a phase change material (PCM) surrounding at least a portion of the traction battery. The traction battery is pre-cooled by circulating refrigerant coolant to the PCM to cool the PCM and thereby pre-cool the traction battery.

Abstract: A vehicle traction battery assembly may include a traction battery cell, a case, and a thermal plate. The case may define a cavity to receive the traction battery cell and has a first side defining a first form feature. The thermal plate may be for positioning adjacent the traction battery cell and define a coolant channel sized for engagement with the case via the first form feature such that traction battery cell is in thermal communication with coolant flowing through the coolant channel. The first form feature may be serpentine-shaped or S-shaped. The first form feature may be castle-shaped from a cross-sectional plan view. The case may be multi-layered and include a first polymer layer, a second polymer layer, and an aluminum layer disposed between the polymer layers.