Abstract: A battery pack includes battery cells and an interconnect board assembly (ICBA) having a dielectric ICB and parallel busbars. A cell tab protrudes from an edge of the cells and joined to the busbars. A dielectric ICB is connected to the busbars at one distal end of the busbars. The dielectric material of the ICB is overmolded onto another distal end such that the ICB wraps around the busbars to form overmolded ends. The overmolded ends are received within a pocket of a bracket to form direct parallel cooling paths to a heat sink. A method of manufacturing the battery pack includes arranging the busbars in parallel, overmolding dielectric material onto ends of the busbars to form overmolded ends, and attaching the busbars to a plastic ICB formed from the dielectric material. The ICBA is then attached to the bracket and cells.

Abstract: A battery pack includes battery cells and an interconnect board assembly (ICBA) having a dielectric ICB and parallel busbars. A cell tab protrudes from an edge of the cells and joined to the busbars. A dielectric ICB is connected to the busbars at one distal end of the busbars. The dielectric material of the ICB is overmolded onto another distal end such that the ICB wraps around the busbars to form overmolded ends. The overmolded ends are received within a pocket of a bracket to form direct parallel cooling paths to a heat sink. A method of manufacturing the battery pack includes arranging the busbars in parallel, overmolding dielectric material onto ends of the busbars to form overmolded ends, and attaching the busbars to a plastic ICB formed from the dielectric material. The ICBA is then attached to the bracket and cells.

Abstract: A thermal barrier for use in a power module assembly having at least one battery cell and corresponding method of forming. The thermal barrier includes at least one compressible member having one or more pockets. A first layer and a second layer are positioned adjacent to the compressive member at a first side and a second side, respectively. The thermal barrier includes one or more phase change materials configured to be deposited into the pockets. The phase change materials are configured to undergo an endothermic phase change reaction when a temperature is at or above an activation temperature. The first layer and the second layer may be configured to at least partially reflect radiant heat. In one example, the phase change materials include a bicarbonate salt.

Abstract: A cooling plate distributes a coolant for an electrical battery, and is defined by parallel first and second edges and parallel third and fourth edges. A coolant inlet is arranged at a junction between the first and fourth edges, and a coolant outlet arranged at a junction between the second and fourth edges. A first coolant channel is arranged along the first edge, in direct communication with the inlet, and a second coolant channel is arranged along the second edge, in direct communication with the outlet. First and second sets of coolant mini-channels are in direct communication with the second channel. A first coolant manifold, arranged proximate the third edge, is in direct communication with the first channel. A second coolant manifold, arranged proximate the fourth edge, is in direct communication with the inlet. The two manifolds are in communication with the outlet via the respective sets of mini-channels.

Abstract: A cooling plate distributes a coolant for an electrical battery, and is defined by parallel first and second edges and parallel third and fourth edges. A coolant inlet is arranged at a junction between the first and fourth edges, and a coolant outlet arranged at a junction between the second and fourth edges. A first coolant channel is arranged along the first edge, in direct communication with the inlet, and a second coolant channel is arranged along the second edge, in direct communication with the outlet. First and second sets of coolant mini-channels are in direct communication with the second channel. A first coolant manifold, arranged proximate the third edge, is in direct communication with the first channel. A second coolant manifold, arranged proximate the fourth edge, is in direct communication with the inlet. The two manifolds are in communication with the outlet via the respective sets of mini-channels.

Abstract: A thermal barrier for use in a power module assembly having at least one battery cell and corresponding method of forming. The thermal barrier includes at least one compressible member having one or more pockets. A first layer and a second layer are positioned adjacent to the compressive member at a first side and a second side, respectively. The thermal barrier includes one or more phase change materials configured to be deposited into the pockets. The phase change materials are configured to undergo an endothermic phase change reaction when a temperature is at or above an activation temperature. The first layer and the second layer may be configured to at least partially reflect radiant heat. In one example, the phase change materials include a bicarbonate salt.