Abstract: An assembly includes a busbar of a traction battery pack, and at least one terminal of a battery cell of the traction battery pack. The at least one terminal is electrically coupled to the busbar. The assembly further includes a thermal exchange plate, and a thermal interface material that communicates thermal energy to the thermal exchange plate from the at least one terminal, from the busbar, or both.

Abstract: A battery pack sensing module includes a rigid printed circuit board that is to be carried by and bridge between a pair of battery cell arrays, a plurality of integrated circuits mounted on the rigid printed circuit board, and a pair of sense lead connectors at opposite ends of the rigid printed circuit board. Each of the sense lead connectors is electrically connected with at least one of the integrated circuits and can mate with a receiving connector of one of the battery cell arrays to establish an electrical connection between the receiving connector and the at least one of the integrated circuits.

Abstract: A traction battery assembly includes, among other things, a cover of a battery array, a holder attached to the cover, and a circuit board held by the holder in a position where the circuit board is spaced from the cover. The holder is configured to communicate thermal energy between the circuit board and the cover. A method of securing a circuit board of a traction battery pack includes, among other things, holding a circuit board with a holder, and attaching a holder that is holding the circuit board to a cover of a battery array. The circuit board held by the holder is held in a position where the circuit board is spaced from the cover.

Abstract: A traction battery assembly according to an exemplary aspect of the present disclosure includes a lower tier of battery arrays, an upper tier of battery arrays, and a support structure disposed between the lower tier and the upper tier. The lower tier is suspended from a downwardly facing side of the support structure. The upper tier is disposed atop an upwardly facing side of the support structure.

Abstract: A service tool assembly according to an exemplary aspect of the present disclosure includes, among other things, a service tool that extends through an access hole in a floor of an electrified vehicle and is adapted to engage a threaded hole of a battery pack. The service tool is rotatable to translate the battery pack relative to the electrified vehicle.

Abstract: A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, an array of battery cells, with each cell including a terminal, and a busbar assembly having a first busbar component and a second busbar component. Further, each of the terminals are electrically coupled to both the first busbar component and the second busbar component. A method of forming a busbar assembly is also disclosed.

Abstract: A battery pack assembly includes battery cells, a first endplate adjacent a first end of the battery cells, a second endplate adjacent an opposite, second end of the battery cells, and a tension member. The first and second endplates are each slidably coupled to the tension member. A compressible member is disposed between the first endplate and a section of an enclosure. The compressible member is configured to compress in response to the battery cells expanding and moving the first endplate toward the section of the enclosure.

Abstract: A delivery system includes a processor programmed to construct a route so as to include predefined segments traveled by carriers configured to taxi the vehicle and charge a battery thereof such that a state of charge of the battery remains above a target for a duration of the route, and forward the route to the vehicle.

Abstract: A traction battery assembly includes, among other things, a battery cell array having a plurality of individual battery cells. The battery cell array usable with a first busbar module having a first arrangement of busbars. The battery cell array is also usable with a second busbar module having a second arrangement of busbars. When the battery cell array is used with the first busbar module, the battery cell array is partitioned into a first number of groups of battery cells in parallel with each other. When the battery cell array is used with the second busbar module, the battery cell array is partitioned into a different, second number of groups of battery cells in parallel with each other.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a sense lead assembly having a circuit board that is centrally mounted between first and second wiring members (e.g., flat flexibles cables or flat printed circuits). The circuit board establishes a suitable mounting surface for incorporating sense lead fuses into the sense lead assembly. The centralized sense lead fuses provide for simple and reliable servicing of the battery array in response to battery overcurrent conditions.

Abstract: Battery array designs for electrified vehicle battery packs may include a thermal interface material disposed between battery cells of the array and both a top plate and a bottom plate of an array support structure. The battery array may therefore be configured to transfer heat through the top, bottom, or both. The battery array may further include a mounting flange located an equal distance from both the top plate and the bottom plate along a side plate of the array support structure. The battery array therefore provides a symmetrical design that simplifies assembly.

Abstract: Exemplary bus bar assemblies may be used to electrically couple adjacent components of electrified vehicle traction battery packs, for example. An exemplary bus bar assembly may include a bus bar and a cover disposed about portions of the bus bar. The bus bar may include a single combined electrical interface section and multiple component electrical interface sections for connecting multiple traction battery pack electrical components in parallel configurations.

Abstract: A traction battery assembly includes battery cells of a battery array, and switches of the battery array. The switches are transitionable between a first configuration and a second configuration. When the switches are in the first configuration, the battery cells of the array are partitioned into a first number of groups of battery cells in parallel with each other. When the switches are in the second configuration, the battery cells of the array are partitioned into a different, second number of groups of battery cells in parallel with each other.

Abstract: A traction battery assembly includes, among other things, an array sense lead header of a battery array, a plurality of sense leads extending from the array sense lead header to areas of the battery array, and a battery pack module having a module connector. The battery pack module is configured to move relative to the battery array from a disengaged position where the module connector the array sense lead header are disengaged to an engaged position where the module connector and the array sense lead header are engaged.

Abstract: A traction battery assembly according to an exemplary aspect of the present disclosure includes a lower tier of battery arrays, an upper tier of battery arrays, and a support structure disposed between the lower tier and the upper tier. The lower tier is suspended from a downwardly facing side of the support structure. The upper tier is disposed atop an upwardly facing side of the support structure.

Abstract: A traction battery assembly includes, among other things, a cover of a battery array, a holder attached to the cover, and a circuit board held by the holder in a position where the circuit board is spaced from the cover. The holder is configured to communicate thermal energy between the circuit board and the cover. A method of securing a circuit board of a traction battery pack includes, among other things, holding a circuit board with a holder, and attaching a holder that is holding the circuit board to a cover of a battery array. The circuit board held by the holder is held in a position where the circuit board is spaced from the cover.

Abstract: A vehicle has a battery including a plurality of cells connected in series, and a battery management integrated circuit including a plurality of inputs each being directly electrically connected to a terminal of one of the cells via an electrical path that includes a fuse and a resistor connected in series. The battery management integrated circuit further includes a top input directly electrically connected to a positive output of the battery and configured to receive power from the battery that is defined by a current having a magnitude that is at least an order of magnitude greater than current received by the inputs and a voltage equal to a sum of voltages of all the cells.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may incorporate one or more temperature regulated current shunts for measuring current flow into and out of battery cells of the battery pack. The temperature of the current shunt can be regulated by a liquid cooling system associated with the battery pack.

Abstract: A traction battery assembly includes, among other things, a battery cell array having a plurality of individual battery cells. The battery cell array usable with a first busbar module having a first arrangement of busbars. The battery cell array is also usable with a second busbar module having a second arrangement of busbars. When the battery cell array is used with the first busbar module, the battery cell array is partitioned into a first number of groups of battery cells in parallel with each other. When the battery cell array is used with the second busbar module, the battery cell array is partitioned into a different, second number of groups of battery cells in parallel with each other.

Abstract: A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, an array of battery cells, with each cell including a terminal, and a busbar assembly having a first busbar component and a second busbar component. Further, each of the terminals are electrically coupled to both the first busbar component and the second busbar component. A method of forming a busbar assembly is also disclosed.