Abstract: A spigot assembly for connecting a coolant flow conduit to a rechargeable battery thermal management system includes a male spigot, a coolant spigot having a connector body defining an internal coolant flow cavity and having a conduit connection end opening and a male spigot connection end opening. The spigot assembly includes a ceramifiable silicone rubber seal. The connector body is configured to receive the male spigot within the internal coolant flow cavity at the male spigot connection end opening, with the ceramifiable silicone rubber seal disposed between and sealing against an outer side of the male spigot and an inner side of the connector body. A spigot assembly is disclosed that has a collar surrounding the connector body. The collar has an angled inner wall configured to align the male spigot with the connector body and shield the seal from heat. A vehicle having the spigot assembly is disclosed.

Abstract: Aspects of the disclosure include systems and methods that leverage adjacent component heating to accelerate the cure time of thermal interface adhesives. An exemplary method can include receiving a battery pack and a thermal management system including a cooling plate, an upper tray, and a lower tray joined to opposite surfaces of the cooling plate to define an enclosed volume therebetween. The method includes wetting an interface between the battery pack and the thermal management system with an adhesive and joining the battery pack to the thermal management system at the interface. The method includes directing a heating fluid through the enclosed volume, thereby heating the adhesive. The method includes, responsive to determining that a temperature of the adhesive has reached a target temperature, maintaining the temperature for a soak time according to a cure curve of the adhesive to achieve a target bond strength.

Abstract: A blow molded article of manufacture includes first and second battery enclosures each having respective first and second laterally outward extending flanges, and a parison made of a polymeric material. The first and second battery enclosure components are disposed facing each other and with their respective first and second laterally outward extending flanges registered with each other and spaced apart from each other by an offset. The parison is sandwiched between and connects together the first and second battery enclosure components, such that the parison conforms with interior surfaces of the battery enclosure components and with the parison substantially filling the offset. The article of manufacture may be cut along a cut line through the parison and within the offset around an outer perimeter of the article of manufacture, thereby separating the article of manufacture into first and second battery enclosure assemblies. Methods of formation are also disclosed.

Abstract: Aspects of the disclosure include systems and methods that leverage adjacent component heating to accelerate the cure time of thermal interface adhesives. An exemplary method can include receiving a battery pack and a thermal management system including a cooling plate, an upper tray, and a lower tray joined to opposite surfaces of the cooling plate to define an enclosed volume therebetween. The method includes wetting an interface between the battery pack and the thermal management system with an adhesive and joining the battery pack to the thermal management system at the interface. The method includes directing a heating fluid through the enclosed volume, thereby heating the adhesive. The method includes, responsive to determining that a temperature of the adhesive has reached a target temperature, maintaining the temperature for a soak time according to a cure curve of the adhesive to achieve a target bond strength.

Abstract: A spigot assembly for connecting a coolant flow conduit to a rechargeable battery thermal management system includes a male spigot, a coolant spigot having a connector body defining an internal coolant flow cavity and having a conduit connection end opening and a male spigot connection end opening. The spigot assembly includes a ceramifiable silicone rubber seal. The connector body is configured to receive the male spigot within the internal coolant flow cavity at the male spigot connection end opening, with the ceramifiable silicone rubber seal disposed between and sealing against an outer side of the male spigot and an inner side of the connector body. A spigot assembly is disclosed that has a collar surrounding the connector body. The collar has an angled inner wall configured to align the male spigot with the connector body and shield the seal from heat. A vehicle having the spigot assembly is disclosed.