Abstract: A battery pack assembly includes a cell stack assembly including a plurality of battery cells disposed along a cell stack axis. A busbar frame is joined to the cell stack assembly. The busbar frame includes at least one relief notch that accommodates movement of the cell stack assembly relative to the frame. At least one joint can connect the busbar frame to the endplate. The at least one relief notch can be configured to accommodate movement of the at least one joint when the endplate is moved axially relative to the busbar frame.

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: Battery array end plate designs are disclosed for use within traction battery packs. An exemplary battery array of the traction battery pack may include features that facilitate a battery array assembly process. These features include channels for accommodating a compression fixture, interlocking features (ribs, bumps, pins, etc.) for engaging corresponding features of an array housing, and angled walls for compressing an upper portion of a cell stack during the battery array assembly process.

Abstract: Battery array busbar frame designs are disclosed for use within traction battery packs. An exemplary battery array may include a busbar frame that includes features that facilitate the use of mechanical fastenerless connections inside the battery array. These features may include legs that can be mounted to a top cover and/or bottom cover of an array housing via an adhesive, and holders that provide an interface for connecting cell spacers to the busbar frame in order to mitigate busbar frame and/or cell spacer motion and increase the structural integrity of the battery array. Gaps between adjacent legs of the busbar frame may further establish coolant flow passages for directing a coolant around battery cells in order to thermally manage the battery array.

Abstract: A battery pack terminal shield assembly includes an anchoring section, a first terminal cap connected to the anchoring section, and a second terminal cap connected to the anchoring section. The anchoring section is configured to secure the first terminal cap and the second terminal cap relative to an array of traction battery pack.

Abstract: A traction battery assembly includes an array housing that houses battery cells, and a filter layer permitting a flow of gas vented from at least one of the battery cells to an area outside the array housing. The filter layer blocks a flow of particulates vented from the at least one battery cell to the area outside the array housing.

Abstract: A traction battery pack assembly includes an enclosure and a cell stack within an interior of the enclosure. The cell stack includes battery cells and divider assemblies disposed along a cell stack axis. The divider assemblies are each sandwiched along the axis between a first battery cell and a second battery cell. The divider assemblies each interface with an axially facing side of the first battery cell and an axially facing side of the second battery cells to support the battery cells at a position spaced from the enclosure.

Abstract: An electrochemical system having a thermal barrier layer is provided. The thermal barrier layer includes a polymer network having an inorganic portion and an organic portion such as silicone or a polysiloxane polymer network. The polymer network may further include filler component dispersed therein such as oxidized polyacrylonitrile milled fiber, Aerogel, hollow glass microspheres, and mica.

Abstract: A battery pack may include a busbar including a slot. A battery pack may include a battery cell including a housing and a tab terminal extending from the housing in a first direction, wherein the tab terminal includes a plurality of fingers spaced-apart from one another in a second direction perpendicular to the first direction, and wherein each of the plurality of fingers is in direct contact with the busbar.

Abstract: Busbar modules are provided for electrically connecting battery cells of a battery system for a traction battery pack. The busbar modules may include a scalable design for accommodating battery systems of all sizes and design requirements. An exemplary busbar module may include a busbar frame and a busbar system positionable relative to a grouping of battery cells by the busbar frame. The busbar system may include a negative terminal, a positive terminal, a plurality of short busbars, and a long busbar.

Abstract: Battery cell tab terminal-to-busbar configurations are provided for electrically connecting battery cells within a traction battery pack. The tab terminals may be secured to the busbar within a space that extends between the battery cells and the busbar in order to reduce the amount of packaging space required for electrically connecting the battery cells and thus reduce the overall tab terminal-to-busbar footprint. In one implementation, the tab terminals are secured to a flat surface of the busbar and are forced into contact with the flat surface by a backing plate. In other implementations, the tab terminals are secured to angled portions of the busbar.

Abstract: A busbar assembly includes a busbar core configured to electrically couple a first component to a second component. The busbar core has a first connection portion that directly connects the busbar core to the first component, a second connection portion that directly connects the busbar core to the second component. A thermal barrier system covers the busbar core including the first connection portion, the second connection portion, or both.

Abstract: A battery pack assembly includes a first battery array, a second battery array adjacent the first battery array, and a thermal barrier assembly that blocks transfer of thermal energy between the first battery array and the second battery array. The thermal barrier assembly having a sheet of material that is folded to provide a plurality of layers.

Abstract: Electrochemical cell arrays such as battery packs having cells of different sizes and/or thicknesses is disclosed. For example, the cells in an array may progressively increase or decrease in size or thickness from a first end to a second end such that a gradient in thickness is created. Alternatively, the gradient may be from the center to the outside. In a variation, the first and second endplates may be of different sizes or thicknesses.

Abstract: Exemplary battery cell tab terminal and busbar configurations are provided for electrically connecting battery cells within a traction battery pack. An exemplary battery cell may include a tab terminal having a tab end section shaped to provide a local thickness increase that is adapted for reducing weld spatter and increasing weld quality when welding the tab terminal to a busbar. The busbar may include a weld joint backing structure that facilitates positioning and welding the tab terminal to the busbar.

Abstract: A device may include an enclosure assembly providing an interior that houses at least one battery array. A device may include a pressure relief valve that communicates a flow of vent byproducts from the interior of the enclosure assembly when the pressure relief valve is in an open position. A device may include a filtering system having at least one first filter that filters the flow and at least one second filter that filters the flow, the first filter having a first permeability, the second filter having a second permeability that is different than the first permeability.

Abstract: A traction battery includes a battery array and a flexible printed circuit (FPC). The FPC including a hurdle-shaped flexible substrate that is planar and has opposing first and second planar surfaces and opposing first and second edges extending between the planar surfaces, the substrate having a straight middle portion, a first end portion that is joined to the middle portion by a first elbow portion, and a second end portion that is joined to the middle portion by a second elbow portion. The elbow portions are folded relative to the middle portion at first and second folds, respectively, such that the first planar surfaces of the first and second elbows face each other. A circuit is supported by the substrate and electrically connected between circuit boards supported on opposite sides of the battery array.

Abstract: Busbars are provided for electrically connecting battery cells within a traction battery pack. An exemplary busbar may include features for locating and positioning a tab terminal of a battery cell. For example, the busbar may include a slot and a bent portion. The tab terminal may be received within the slot such that at least a portion of the tab terminal is positioned on an opposite side of the busbar from a housing of the battery cell. The tab terminal may be secured (e.g., welded) to the bent portion at a section of the busbar that is exposed within the slot.

Abstract: Integrated filtering systems are provided for filtering battery vent byproducts (e.g., gases and/or effluent particulates) during battery thermal events of a traction battery pack. The filtering systems may include one or more filters integrated as part of a vent valve, a vent pipe, a pressure equalization device, and/or an array housing of the traction battery pack, and/or as part of a structure that is separate from the traction battery pack. The filter may be configured to filter a constituent element (e.g., carbon monoxide (CO), hydrogen fluoride (HF), etc.) of a gaseous mixture vented from a battery cell of the traction battery pack during a battery thermal event, thereby mitigating the potential for vent gas combustion. The filter may be further configured to control the escape of particulates to surrounding environments.

Abstract: A traction battery includes a stack of cells each having two terminals. Sets of terminals are connected to busbars to electrically connect the battery cells. The busbars have a base, a set of connecting portions, and a set of stiffeners. The terminals have protruding portions and receding portions. As the busbar is positioned with respect to the battery stack, the connecting portions guide the receding portions into position by deflecting the protruding portions. The receding portions are then welded to the connecting portions. The deflected protruding portion forces the parts to be welded together, eliminating a need for clamping during the welding process.