Abstract: An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a battery support structure to support a plurality of battery cells, wherein the battery support structure includes opposing longitudinal sides and opposing lateral sides. A first extrusion is positioned to extend along at least one of the opposing longitudinal and lateral sides. A second extrusion is connected to the first extrusion such that the first extrusion is located between the plurality of battery cells and the second extrusion.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include an enclosure assembly, one or more battery arrays housed within the enclosure assembly, and one or more channel brackets for routing and retaining battery internal components (e.g., wiring harnesses, etc.) within internal channels of the battery pack. The channel brackets may include a mounting platform having a loop that is connected to the mounting platform by a tether. A clip fastener may be received through both the loop and the mounting platform for mounting the channel brackets in place. The loop of the channel bracket is configured to increase the integrity of the clip fastener joint.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include an enclosure assembly that houses one or more battery arrays. An impact protection shroud is mounted to a portion of at least one of the battery arrays. A battery sensitive component is at least partially covered by the impact protection shroud. The impact protection shroud is configured to establish minimum clearances relative the battery sensitive component and to redirect loads away from the battery sensitive component, thereby protecting the battery sensitive component during vehicle impact loading events.

Abstract: Reinforcement assemblies and associated methods are provided for reinforcing a battery pack of an electrified vehicle. An exemplary battery pack may include a battery internal component (e.g., a battery array), an enclosure assembly for housing the battery internal component, and a reinforcement assembly secured to the enclosure assembly. The reinforcement assembly may include a beam and a bracket secured to the beam. The reinforcement assembly may be positioned at expected high impact load locations of the enclosure assembly and is configured for absorbing and transferring energy during vehicle impact loading events, thereby minimizing transfer of the impact loads inside the battery pack where relatively sensitive battery internal components are housed.

Abstract: Exemplary traction battery pack designs are disclosed for use in electrified vehicles. Exemplary traction battery packs may include an outer enclosure assembly establishing an interior, a battery array housed within the interior, a battery internal structure adjacent to the battery array, and a carrier plate assembly arranged to secure the battery array to the battery internal structure. The carrier plate assembly may include a carrier plate and a floating cage nut. The cage nut may accommodate a fastener for securing the battery array to the battery internal structure.

Abstract: A multi-tier traction battery support assembly includes, among other things, a lower-tier battery array, an intermediate bracket directly secured to at least one endplate of the lower-tier battery array, and an upper-tier battery array supported on the intermediate bracket. A multi-tier traction battery support method includes supporting an intermediate bracket with at least one endplate of a lower-tier battery array and supporting an upper battery array with the intermediate bracket. The intermediate bracket is secured directly to the at least one endplate.

Abstract: A battery assembly includes, among other things, an enclosure having a floor, and battery cell frames disposed along an axis within the enclosure. Each of the battery cell frames includes a frame foot that projects laterally outward. An endplate is at an axial end of the battery cell frames. The endplate includes an endplate retention flange that projects laterally outward to laterally overlap with a portion of the retention member. A retention member extends axially alongside the battery cell frames. The retention member includes a lip that projects laterally inward across the frame feet such that the frame feet are held between the lip and the floor. An axial end portion of the retention member is secured directly to the endplate retention flange.

Abstract: An electrified vehicle assembly includes, among other things, a traction battery, and at least one shield extending longitudinally and having a portion that is vertically beneath the traction battery. The shield is removably fastened directly to the traction battery.

Abstract: A battery assembly includes, among other things, a tray having a floor, a lid secured to the tray to provide an enclosure having an interior, and a battery module disposed within the interior. The battery module has a plurality of battery cell frames disposed along a battery module axis. The battery cell frames each include a frame toe that projects horizontally. The battery assembly further includes a cross-member disposed within the interior adjacent to the battery module. The cross-member includes a vertically extending wall having a protrusion that is vertically aligned with the frame toes of the plurality of battery cell frames.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include an enclosure assembly, one or more battery arrays housed within the enclosure assembly, a first battery internal component (e.g., an array holding device, heat exchanger plate, tray, etc.) adjacent to the battery array, a mounting bracket mounted to the first battery internal component, and a second battery internal component (e.g., a wiring harness of an electrical distribution system) elevated above the first battery internal component by the mounting bracket.

Abstract: Reinforcement assemblies and associated methods are provided for reinforcing a battery pack of an electrified vehicle. An exemplary battery pack may include a battery internal component (e.g., a battery array), an enclosure assembly for housing the battery internal component, and a reinforcement assembly secured to the enclosure assembly. The reinforcement assembly may include a beam and a bracket secured to the beam. The reinforcement assembly may be positioned at expected high impact load locations of the enclosure assembly and is configured for absorbing and transferring energy during vehicle impact loading events, thereby minimizing transfer of the impact loads inside the battery pack where relatively sensitive battery internal components are housed.

Abstract: A multi-tier traction battery support assembly includes, among other things, a lower-tier battery array, an intermediate bracket directly secured to at least one endplate of the lower-tier battery array, and an upper-tier battery array supported on the intermediate bracket. A multi-tier traction battery support method includes supporting an intermediate bracket with at least one endplate of a lower-tier battery array and supporting an upper battery array with the intermediate bracket. The intermediate bracket is secured directly to the at least one endplate.

Abstract: An electrified vehicle assembly includes, among other things, a traction battery, and at least one shield extending longitudinally and having a portion that is vertically beneath the traction battery. The shield is removably fastened directly to the traction battery.

Abstract: This disclosure details reinforcement assemblies and associated methods for reinforcing a battery pack of an electrified vehicle. An exemplary battery pack may include a battery internal component (e.g., a battery array), an enclosure assembly for housing the battery internal component, and a reinforcement assembly secured to the enclosure assembly. The reinforcement assembly may include a beam and a bracket secured to the beam. The reinforcement assembly may be positioned at expected high impact load locations of the enclosure assembly and is configured for absorbing and transferring energy during vehicle impact loading events, thereby minimizing transfer of the impact loads inside the battery pack where relatively sensitive battery internal components are housed.

Abstract: A battery assembly includes, among other things, an upper tier tray, an upper battery module supported on the upper tier tray, and a post that supports the upper tier tray. A battery module support method according to another exemplary aspect of the present disclosure includes, among other things, supporting an upper tier tray with a post; and supporting an upper battery module with the upper tier tray.

Abstract: A battery pack mounting system includes, among other things, an outboard bracket connecting a battery pack to a vehicle underbody, a first inboard bracket connecting the battery pack to the vehicle underbody, and a second inboard bracket connecting the battery pack to a tunnel of the vehicle underbody.

Abstract: A battery pack assembly includes, among other things, an enclosure providing an interior area that houses one or more battery arrays, a bracket secured relative to the enclosure, and a bracket fastener having a stem extending longitudinally from a head along a longitudinal axis of the bracket fastener. The head is enlarged radially relative to the stem. The head is captured between the bracket and a surface of the enclosure. A battery pack securing method includes, among other things, securing a bracket relative to an enclosure of a battery pack to capture a head of a bracket fastener between the bracket and a surface of an enclosure. The bracket fastener has a stem that extends longitudinally from the head of the bracket fastener.

Abstract: A battery assembly includes, among other things, an enclosure having a floor, and battery cell frames disposed along an axis within the enclosure. Each of the battery cell frames includes a frame foot that projects laterally outward. An endplate is at an axial end of the battery cell frames. The endplate includes an endplate retention flange that projects laterally outward to laterally overlap with a portion of the retention member. A retention member extends axially alongside the battery cell frames. The retention member includes a lip that projects laterally inward across the frame feet such that the frame feet are held between the lip and the floor. An axial end portion of the retention member is secured directly to the endplate retention flange.

Abstract: A battery pack mounting system includes, among other things, a bracket having a first connection flange configured to connect to a vehicle structure, a second connection flange configured to connect to a battery pack, and a spanner portion spanning from the first connection flange to the second connection flange. The bracket includes one or more openings that segment the bracket into at least a first section and a second section. Each of the openings extends into both the spanner portion and the first connection flange.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include an enclosure assembly, one or more battery arrays housed within the enclosure assembly, and one or more channel brackets for routing and retaining battery internal components (e.g., wiring harnesses, etc.) within internal channels of the battery pack. The channel brackets may include a mounting platform having a loop that is connected to the mounting platform by a tether. A clip fastener may be received through both the loop and the mounting platform for mounting the channel brackets in place. The loop of the channel bracket is configured to increase the integrity of the clip fastener joint.