Abstract: An exemplary battery assembly includes, among other things, a first array of battery cells distributed along a first axis, and a second array of battery cells distributed along a second axis laterally spaced from the second axis. A thermal exchange plate is disposed between the first and second arrays. An endplate spans across at least a portion of axially facing end of both the first and second array. An exemplary securing method includes, among other things, positioning a first array of battery cells adjacent a first side of a thermal exchange plate, and a second array of battery cells adjacent an opposite, second side of the thermal exchange plate. The method includes securing the first and second arrays with an endplate spanning across axially facing ends of the both the first and second arrays.

Abstract: An exemplary method includes, among other things, winding a curable material at least partially about a plurality of battery cells that are compressed by a fixture. An exemplary assembly includes, among other things, a plurality of battery cells compressed by a fixture, and a curable material wound around the plurality of battery cells.

Abstract: An exemplary support assembly includes a first housing that supports a first battery structure, a second housing that supports a second battery structure, a cover, and a common attachment that secures together the first housing, the second housing, and the cover. An exemplary support method includes securing together a first housing, a second housing, and a cover with a common attachment. The first housing supports a first battery structure that is enclosed by the second housing. The second housing supports a second battery structure that is enclosed by the cover.

Abstract: An exemplary method includes, among other things, winding a curable material at least partially about a plurality of battery cells that are compressed by a fixture. An exemplary assembly includes, among other things, a plurality of battery cells compressed by a fixture, and a curable material wound around the plurality of battery cells.

Abstract: A battery array according to an exemplary aspect of the present disclosure includes, among other things, a circuit connector assembly and a cover that partially covers the circuit connector assembly. The cover includes a groove. A sense-line wire is received within the groove.

Abstract: An exemplary battery assembly includes an endwall, an endplate, and a flange secured within a recess to secure the endwall relative to the endplate. One of the endwall or the endplate provides the flange, and the other of the endwall or the endplate provides the recess.

Abstract: A battery pack according to an exemplary aspect of the present disclosure includes, among other things, an enclosure and a battery assembly retained relative to the enclosure. One of the battery assembly and the enclosure includes a groove configured to receive a flange of the other of the battery assembly and the enclosure as the battery assembly is slid into engagement with the enclosure.

Abstract: A battery pack according to an exemplary aspect of the present disclosure includes, among other things, an electronics module and an electronics umbrella positioned to channel moisture away from the electronics module.

Abstract: An exemplary battery assembly includes an endplate of a battery array, and an enclosure wall secured directly to the endplate from outside an open area of a battery pack enclosure. An exemplary method of securing a battery array includes positioning a battery array within an open area of an enclosure and, from a position outside the open area, securing an endplate of a battery array directly to a wall of a battery pack enclosure.

Abstract: A vehicle includes a floor and an aluminum battery enclosure. The enclosure has L-shaped formed side walls each at least partially defining a traction battery cavity and including a foot attached to the floor. Each of the feet extends an entire length of the corresponding side wall to distribute impact energy along the entire length to maintain a relative position between the floor and enclosure.

Abstract: A vehicle includes a floor and an aluminum battery enclosure. The enclosure has L-shaped formed side walls each at least partially defining a traction battery cavity and including a foot attached to the floor. Each of the feet extends an entire length of the corresponding side wall to distribute impact energy along the entire length to maintain a relative position between the floor and enclosure.

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 assembly includes a thermal plate having a pair of opposing thermal surfaces and a coolant flow field defined therebetween. Each of the thermal surfaces defines at least one threaded hole that extends into the flow field. The battery assembly further includes first and second cell arrays each disposed against a different one of the thermal surfaces and attached to the thermal plate via a fastener received in one of the threaded holes.

Abstract: An exemplary assembly includes a cord and a lockable charger housing, which has a surface that is shaped to correspond with a shape of a portion of an electrified vehicle. An exemplary method includes positioning a surface of a lockable charger housing against a portion of an electrified vehicle. The surface has a shape corresponding to a shape of a portion of the electrified vehicle. The method includes securing the lockable charger housing relative to the portion after the positioning.

Abstract: A traction battery includes a cell having a terminal defining a surface with a top and at least one sidewall. The traction battery also includes a busbar having an interior defining a top engaging with the top of the terminal, and at least one side surface engaging with the sidewall. One of the side surface and the sidewall includes a projection and the other of the side surface and the sidewall includes a receptacle for receiving the projection.

Abstract: A traction battery includes a cell having a terminal defining a surface with a top and at least one sidewall. The traction battery also includes a busbar having an interior defining a top engaging with the top of the terminal, and at least one side surface engaging with the sidewall. One of the side surface and the sidewall includes a projection and the other of the side surface and the sidewall includes a receptacle for receiving the projection.

Abstract: An exemplary assembly includes a cord and a lockable charger housing, which has a surface that is shaped to correspond with a shape of a portion of an electrified vehicle. An exemplary method includes positioning a surface of a lockable charger housing against a portion of an electrified vehicle. The surface has a shape corresponding to a shape of a portion of the electrified vehicle. The method includes securing the lockable charger housing relative to the portion after the positioning.

Abstract: A traction battery assembly includes a tray and a pair of adjacent cell arrays disposed on the tray. Each array includes a plurality of stacked cells and a plurality of cell spacers interleaved with the cells. A portion of each of the spacers of one of the arrays is inserted into one of the spacers of the other of the arrays to form a plurality of end-to-end connected spacer pairs configured to secure the arrays together.

Abstract: A battery array according to an exemplary aspect of the present disclosure includes, among other things, a circuit connector assembly and a cover that partially covers the circuit connector assembly. The cover includes a groove. A sense-line wire is received within the groove.