Abstract: A thermally conductive bracket is contemplated for use in a vehicle to facilitate transfer heat from a busbar to a cold plate, such as to assist with heat transfer to a cold plate used to act as a heat sink for a plurality of battery cells connected to the busbar. The bracket may include a thermally conductive heat transfer material shaped to receive the busbar where at least a portion of the material is configured to include opposed sides and a bottom such that the opposed sides are configured to transfer heat from the busbar to the bottom and the bottom is configured to transfer heat from the sides to the cold plate.

Abstract: Presented are integrated electrical interconnect board (ICB) assemblies for battery modules, rechargeable traction battery packs equipped with such ICB assemblies, and methods for making/using such ICB assemblies. A battery module for storing and supplying electrical energy includes multiple battery cells that are stacked in side-by-side facing relation with one another and each has a battery cell casing with an electrical terminal projecting therefrom. An electrically insulating module housing has a housing base that supports thereon the stacked battery cells. An integrated ICB assembly, which is attached to the module housing, includes a central cover in spaced facing relation to the housing base, endwalls projecting from the central cover, and multiple busbar connectors attached to the endwalls and electrically connected to the battery cells' electrical terminals.

Abstract: A cell stack includes adjacent first and second battery cells respectively having a positive cell tab, a negative cell tab, and an outer surface. The outer surfaces are flush. The positive cell tab of the first battery cell protrudes from the outer surface of the first battery cell, and the negative cell tab of the second battery cell protrudes from the outer surface of the second battery cell. An isolative shield is positioned adjacent to the outer surfaces, and defines through-slots receiving therein a respective one of the cell tabs. A method includes providing the cell stack, inserting the cell tabs into the pair of through-slots of the isolative shield, positioning a primary surface of the isolative shield adjacent to the outer surfaces of the adjacent battery cells after inserting the cell tabs, and affixing the primary surface of the isolative shield to the cell stack.

Abstract: Presented are integrated electrical interconnect board (ICB) assemblies for battery modules, rechargeable traction battery packs equipped with such ICB assemblies, and methods for making/using such ICB assemblies. A battery module for storing and supplying electrical energy includes multiple battery cells that are stacked in side-by-side facing relation with one another and each has a battery cell casing with an electrical terminal projecting therefrom. An electrically insulating module housing has a housing base that supports thereon the stacked battery cells. An integrated ICB assembly, which is attached to the module housing, includes a central cover in spaced facing relation to the housing base, endwalls projecting from the central cover, and multiple busbar connectors attached to the endwalls and electrically connected to the battery cells' electrical terminals.

Abstract: A cell stack includes adjacent first and second battery cells respectively having a positive cell tab, a negative cell tab, and an outer surface. The outer surfaces are flush. The positive cell tab of the first battery cell protrudes from the outer surface of the first battery cell, and the negative cell tab of the second battery cell protrudes from the outer surface of the second battery cell. An isolative shield is positioned adjacent to the outer surfaces, and defines through-slots receiving therein a respective one of the cell tabs. A method includes providing the cell stack, inserting the cell tabs into the pair of through-slots of the isolative shield, positioning a primary surface of the isolative shield adjacent to the outer surfaces of the adjacent battery cells after inserting the cell tabs, and affixing the primary surface of the isolative shield to the cell stack.

Abstract: Provided herein are battery packs comprising a first polymeric endplate, a second polymeric endplate, and a plurality (n) of partitions extending between the first endplate and second endplate and defining (n?1) battery cavities. Each cavity is capable of receiving a battery cell stack comprising a plurality of battery cells and optionally cooling plates and foam pads. Partitions comprise a plurality of polymeric repeating spacers, and each spacer from each partition can correspond to a cooling plate common to a plurality of battery cell stacks. Each of the repeating spacers and cooling plates can include a plurality of aligned apertures, and corresponding bolts can occupy the aligned apertures and secure the same to the endplates. Each repeating spacer can correspond to a complete or partial battery unit, wherein a complete battery unit comprises a first battery cell, a cooling plate, a second battery cell, and a foam pad.

Abstract: Provided herein are battery packs comprising a first polymeric endplate, a second polymeric endplate, and a plurality (n) of partitions extending between the first endplate and second endplate and defining (n?1) battery cavities. Each cavity is capable of receiving a battery cell stack comprising a plurality of battery cells and optionally cooling plates and foam pads. Partitions comprise a plurality of polymeric repeating spacers, and each spacer from each partition can correspond to a cooling plate common to a plurality of battery cell stacks. Each of the repeating spacers and cooling plates can include a plurality of aligned apertures, and corresponding bolts can occupy the aligned apertures and secure the same to the endplates. Each repeating spacer can correspond to a complete or partial battery unit, wherein a complete battery unit comprises a first battery cell, a cooling plate, a second battery cell, and a foam pad.

Abstract: A trim part is aligned, via a flexible, split jig, to a finished primary surface and adhered by an epoxide to a secondary structural surface. An epoxide fixing accelerant is applied to the epoxide via the jig, whereby the trim part is rapidly rigidly affixed to the secondary structural surface. The jig is then removed via its being both split and resiliently flexed.

Abstract: A trim part is aligned, via a flexible, split jig, to a finished primary surface and adhered by an epoxide to a secondary structural surface. An epoxide fixing accelerant is applied to the epoxide via the jig, whereby the trim part is rapidly rigidly affixed to the secondary structural surface. The jig is then removed via its being both split and resiliently flexed.