Abstract: Exemplary traction battery pack designs are disclosed for use in electrified vehicles. An exemplary traction battery pack may include an outer enclosure assembly that may house one or more battery arrays and/or other battery internal components. The outer enclosure assembly may include a tray having a mixed material or “hybrid” structure that provides a space efficient design. The tray may include a first subassembly made of a first material and a second subassembly made of a second, different material. The first subassembly may include a tub, and the second subassembly may include a heat exchanger plate. Central and perimeter joint strategies may be employed for securing the second subassembly relative to the first subassembly to provide the space efficient design.

Abstract: A traction battery pack assembly includes an enclosure assembly configured to house a plurality of battery cells within an interior area. The enclosure assembly is at least partially provided by a multilayer structure having an apertured core with one or more layers sandwiched between an outer shell and an inner shell. The apertured core has a plurality of apertures. The multilayer structure is at least partially impregnated with a resin.

Abstract: Structural plate member designs are provided for absorbing and distributing energy within traction battery packs. An exemplary structural plate member may include a wall section having a collapsible feature that is configured to collapse to minimize a transfer of energy in a direction toward a battery internal component of the traction battery pack. The structural plate member may be configured to span a plurality of cell stacks of the traction battery pack and may be secured to one or more cell stacks of the plurality of cell stacks for structurally integrating the traction battery pack.

Abstract: The battery structure for an electric vehicle includes battery arrays. A first battery array includes first walls that are secured to each other to form a first unitized structure that is configured to house a first cell stack. One first wall of the first walls includes a first vertical portion, a first upper portion, and a first lower portion. A second battery array includes second walls that are secured to each other to form a second unitized structure that is configured to house a second cell stack. One second wall of the second walls includes a second vertical portion and a second upper portion. The second vertical portion is spaced apart from the first vertical portion. The second upper portion extends toward the first vertical portion from an upper end of the second vertical portion and is secured to the first upper portion of the first battery array.

Abstract: A battery pack assembly includes, among other things, a tray, a lid secured to the tray to provide an enclosure having an interior, at least one battery module disposed within the interior, a cross-member disposed within the interior adjacent to the at least one battery module, and a stanchion secured to the cross-member. The stanchion disposed entirely within the interior. The assembly further includes a fastener that extends through an opening in the lid to engage the stanchion.

Abstract: Exemplary traction battery pack designs are disclosed for use in electrified vehicles. An exemplary traction battery pack may include an outer enclosure assembly that may house one or more battery arrays and/or other battery internal components. The outer enclosure assembly may include a tray having a mixed material or “hybrid” structure that provides a space efficient design. The tray may include a first subassembly made of a first material and a second subassembly made of a second, different material. The first subassembly may include a tub, and the second subassembly may include a heat exchanger plate. Central and perimeter joint strategies may be employed for securing the second subassembly relative to the first subassembly to provide the space efficient design.

Abstract: A battery pack assembly includes, among other things, a tray, a lid secured to the tray to provide an enclosure having an interior, at least one battery module disposed within the interior, a cross-member disposed within the interior adjacent to the at least one battery module, and a stanchion secured to the cross-member. The stanchion disposed entirely within the interior. The assembly further includes a fastener that extends through an opening in the lid to engage the stanchion.