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.

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: 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: A traction battery includes a battery array having a stack of cells, wherein a first of the cells includes a terminal having a projecting portion extending from a body of the cell and a curved portion disposed on a distal end of the projecting portion. A busbar has a connecting portion defining a slot with a pair of first opposing sides and a pair of second opposing sides. The connecting portion further has a pair of flaps, each pivotally attached to one of the second opposing sides such that the flaps oppose each other. The terminal is mechanically joined to the connecting portion with the curved portion of the terminal in contact with at least one of the flaps.

Abstract: A positive electrode material includes a plurality of particles composed of a positive electrode active material and a passivating layer disposed over each particle of the plurality of particles. The passivating layer is thermally insulating and lithium-ion conducting wherein the passivating layer is composed of a carbonate-phosphate composite.

Abstract: A positive electrode for a lithium-ion battery includes a current collector a positive electrode active layer disposed over the current collector. The positive electrode active layer is composed of a positive electrode composition includes a first positive electrode active material that has been aged for a first predetermined time period.

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: A battery pack assembly includes a first battery array, a second battery array adjacent the first battery array, a thermal control assembly that includes a thermal blanket spanning across the first battery array and the second battery array, and a partitioning region of the thermal control assembly. The partitioning region extends to a position between the first battery array and the second battery array. The partitioning region includes a foam core.

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: A battery pack assembly includes battery cells, a thermal barrier adjacent the battery cells, and at least one scored region of the thermal barrier. The scored region is configured to rupture to provide a vent flap that opens to establish a vent path for gas expelled from at least one of the battery cells.

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 battery module locating tool includes a support pillar and a plurality of fixtures supported on the support pillar. Each fixture is individually translatable along the support pillar and arranged to locate a battery cell according to a longitudinal datum and a lateral datum. The support pillar is movable toward and away from a battery frame onto which the battery cell is located.

Abstract: A battery module locating tool includes a support pillar and a plurality of fixtures supported on the support pillar. Each fixture is individually translatable along the support pillar and arranged to locate a battery cell according to a longitudinal datum and a lateral datum. The support pillar is movable toward and away from a battery frame onto which the battery cell is located.

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: 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: An example electric vehicle battery current communication device includes a terminal landing and a transition from the terminal landing having an area that is both bent and tapered. The transition can bend toward an interior of a battery cell such that a portion of the transition is closer to the interior than each portion of the terminal landing. The terminal landing can attach to a bus bar. The terminal landing can also weld to a bus bar. The transition can extend from the terminal landing to a current collector extending into an interior of the battery cell.