Abstract: A battery pack includes a battery array and an enclosure assembly housing the battery array. The enclosure assembly includes a tray, a cover, and a mid-tray. A plurality of internal components are secured within the mid-tray to establish an electrical subassembly within the enclosure assembly.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack assembly process may include supporting one or more components, such as a heat exchanger plate, of the battery pack against deflection during the assembly process. Supporting the heat exchanger plate to keep the plate relatively flat during the battery pack assembly process improves the flow distribution of a thermal interface material (TIM), thereby achieving improved TIM coverage and improved heat transfer between battery cells and the heat exchanger plate of the battery pack.

Abstract: A fluid sensor assembly is provided. The fluid sensor assembly includes a flange, a base, and a cap. The flange is configured to mount to a fluid container. The base is configured to receive a fluid sensor, the base rotatably mounted to the flange and configured to rotate about the flange, the base forming a plurality of receiving apertures positioned about a perimeter of the base. The cap is configured to lock on the base and form a fluid-tight seal between the cap and the base.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a battery system and a passive thermal suppression material system positioned about at least a portion of the battery system. The passive thermal suppression material system is configured to release a thermal suppression material during certain battery thermal events. The thermal suppression material prevents or delays thermal runaway inside the battery pack.

Abstract: A battery module according to an exemplary aspect of the present disclosure includes, among other things, an array of battery cells, a compression structure including a first wall and a second wall, at least one conduit configured to convey fluid adjacent the array, and a tension member connected to the first wall and the second wall. The tension member is adjacent the at least one conduit. This disclosure also relates to an electrified vehicle and a method.

Abstract: A motor vehicle according to an exemplary aspect of the present disclosure includes, among other things, a frame including a rail and an electrical distribution system routed at least partially through the rail. A method is also disclosed.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a battery system and an expandable polymer foam enclosure that substantially encapsulates the battery system. An expandable polymer foam may be introduced into a mold, expand, and then cure around to battery system to form the enclosure.

Abstract: A fluid sensor assembly is provided. The fluid sensor assembly includes a flange, a base, and a cap. The flange is configured to mount to a fluid container. The base is configured to receive a fluid sensor, the base rotatably mounted to the flange and configured to rotate about the flange, the base forming a plurality of receiving apertures positioned about a perimeter of the base. The cap is configured to lock on the base and form a fluid-tight seal between the cap and the base.

Abstract: A dual-sensor fluid sensor assembly is provided. The dual-sensor fluid sensor assembly includes a probe holder, a base, and a spring. The probe holder is configured to receive and secure two fluid sensor probes. The base is configured to receive and secure the holder upon rotation of the holder into the base. The spring is positioned between the holder and the base, the spring being positioned to exert a repelling force between the holder and the base to secure the holder to the base.

Abstract: A fluid sensor assembly is provided. The fluid sensor assembly includes a base and a cap. The base is configured to receive a fluid sensor, the base forming a plurality of receiving apertures positioned about a perimeter of the base. The cap is configured to fit on the base and form a fluid-tight seal between the cap and the base, the cap including a plurality of articulating levers, each articulating lever of the plurality of articulating levers being configured to rotate about a central axis and including a latching feature configured to be inserted into a receiving aperture of the plurality of receiving apertures when the cap is fitted on the base and to lock the cap to the base upon rotation of the articulating levers.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a polymer-based enclosure assembly having features for thermally managing internal components of the battery pack. In some embodiments, the enclosure assembly may include molded-in fluid channels or molded-in tubing for establishing a cooling circuit of the battery pack. In other embodiments, the enclosure assembly may include molded-in channels that receive tubing for establishing a cooling circuit of the battery pack.

Abstract: An exemplary retention assembly includes a plurality of battery cells, a heat exchange structure, and a strap that pulls together the heat exchange structure and the plurality of battery cells.

Abstract: An exemplary attachment method includes, among other things, to electrically couple a first battery cell to a busbar, joining a terminal of the first battery cell to the busbar with a first weld. The method further includes, to electrically couple a second battery cell to the busbar, joining a terminal of the second battery cell to the terminal of the first battery cell with a second weld. An exemplary attachment assembly includes, among other things, a busbar, a first terminal of a first battery cell, and a second terminal of a second battery cell. The first terminal is electrically coupled to the busbar with a first weld that joins the first terminal to the busbar. The second terminal is electrically coupled to the busbar with a second weld that joins the second terminal to the first terminal.

Abstract: A battery array frame according to an exemplary aspect of the present disclosure includes, among other things, a frame body, and a thermal fin including a body embedded in the frame body and a leg that extends outside of the frame body. The thermal fin is flexible between a first position in which the leg is spaced farther from a surface of the frame body and a second position in which the leg is spaced closer to the surface of the frame body.

Abstract: Electrified vehicles such as hybrid electric vehicles (HEV's), plug-in hybrid electric vehicles (PHEV's), battery electric vehicles (BEV's), or fuel cell vehicles differ from conventional motor vehicles in that they are powered by one or more electric machines (i.e., electric motors and/or generators) instead of or in addition to an internal combustion engine. High voltage current for powering these types of electric machines is typically supplied by a high voltage traction battery system having one or more battery cells that store energy.

Abstract: This disclosure details exemplary insulating flexible membranes for use with vehicle high voltage modules. The high voltage modules may include any module that is adapted for supporting electric propulsion within the vehicle. The insulating flexible membranes may be attached to an exterior of a housing, to an interior of the housing, or may be disposed about a high voltage component housed inside the module. The insulating flexible membranes of this disclosure are configured to distort to prevent access to damaged high voltage components of the high voltage modules.

Abstract: An exemplary battery pack assembly includes an endplate with a first side region and a second side region opposite the first side region, a first connector in the first side region, and a second connector in the second side region. The first and second connectors each provide a connection point to secure the endplate to a support when a respective one of the first or second side regions is positioned proximate the support.

Abstract: A battery array frame according to an exemplary aspect of the present disclosure includes, among other things, a frame body, and a thermal fin including a body embedded in the frame body and a leg that extends outside of the frame body. The thermal fin is flexible between a first position in which the leg is spaced farther from a surface of the frame body and a second position in which the leg is spaced closer to the surface of the frame body.

Abstract: A hybrid energy storage and delivery device includes a plastic enclosure that establishes a first sealed chamber and a second sealed chamber. The first sealed chamber is configured as a fuel tank for storing a liquid fuel and the second sealed chamber is configured as a battery pack for storing electrical energy. Thus, the fuel tank and battery pack may be integrated together within a single enclosure in order to improve vehicle packaging efficiencies.

Abstract: An exemplary attachment method includes, among other things, to electrically couple a first battery cell to a busbar, joining a terminal of the first battery cell to the busbar with a first weld. The method further includes, to electrically couple a second battery cell to the busbar, joining a terminal of the second battery cell to the terminal of the first battery cell with a second weld. An exemplary attachment assembly includes, among other things, a busbar, a first terminal of a first battery cell, and a second terminal of a second battery cell. The first terminal is electrically coupled to the busbar with a first weld that joins the first terminal to the busbar. The second terminal is electrically coupled to the busbar with a second weld that joins the second terminal to the first terminal.