Abstract: An exemplary battery assembly includes, among other things, battery cells distributed along an axis and disposed on a base. A bracket extends axially along a side of the battery cells. A plate extends from a first side to an opposing, second side of the battery cells. A retention flange of the plate is held between the bracket and the base. An exemplary method of retaining includes holding battery cells relative to a base using a bracket extending along a side of the array, and positioning a retention flange of a plate between the bracket and the base. A primary portion of the plate is disposed along an axial end of the array.

Abstract: An exemplary battery assembly includes, among other things, a thermal fin, a frame holding the thermal fin, and a stand-off of the frame configured to limit relative movement of the thermal fin toward a thermal exchange plate. An exemplary thermal fin positioning method, includes limiting relative movement of a thermal fin toward a thermal exchange plate using a stand-off disposed upon a battery cell assembly frame.

Abstract: An exemplary thermal interface material installation method includes, among other things, moving a material through a conduit to a cavity within a battery array. The conduit is at least partially provided by a thermal exchange plate of the battery array. The method further includes holding the material within the cavity to provide a thermal interface material between the thermal exchange plate and at least one battery cell assembly. An exemplary battery thermal interface material installation assembly includes a thermal exchange plate including a conduit with at least one inlet that opens to an exterior of a battery array, and at least one outlet that opens to a cavity between the thermal exchange plate and a plurality of battery cell assemblies.

Abstract: An exemplary battery assembly includes, among other things, battery cells distributed along an axis and disposed on a base. A bracket extends axially along a side of the battery cells. A plate extends from a first side to an opposing, second side of the battery cells. A retention flange of the plate is held between the bracket and the base. An exemplary method of retaining includes holding battery cells relative to a base using a bracket extending along a side of the array, and positioning a retention flange of a plate between the bracket and the base. A primary portion of the plate is disposed along an axial end of the array.

Abstract: An exemplary thermal interface material installation method includes, among other things, moving a material through a conduit to a cavity within a battery array. The conduit is at least partially provided by a thermal exchange plate of the battery array. The method further includes holding the material within the cavity to provide a thermal interface material between the thermal exchange plate and at least one battery cell assembly. An exemplary battery thermal interface material installation assembly includes a thermal exchange plate including a conduit with at least one inlet that opens to an exterior of a battery array, and at least one outlet that opens to a cavity between the thermal exchange plate and a plurality of battery cell assemblies.

Abstract: A battery pack includes a battery pack housing defining an interior region with first and second interior spaces and an intermediate space. The battery pack housing includes inlet and outlet apertures communicating with the first and second interior spaces, respectively. The battery pack has a battery module disposed in the first interior space having a first battery cell and a heat exchanger. The heat exchanger defines a first flow path portion therethrough. The battery pack has a fan assembly disposed in the intermediate space having a first electric fan, and a thermally conductive housing disposed in the second interior space that defines a second flow path portion. The first electric fan urges air to flow through the inlet aperture, the first flow path portion, a portion of the first electric fan, the second flow path portion, and the outlet aperture.

Abstract: An exemplary battery assembly includes, among other things, a thermal fin, a frame holding the thermal fin, and a stand-off of the frame configured to limit relative movement of the thermal fin toward a thermal exchange plate. An exemplary thermal fin positioning method, includes limiting relative movement of a thermal fin toward a thermal exchange plate using a stand-off disposed upon a battery cell assembly frame.

Abstract: A battery pack having a cooling plate assembly and a battery module is provided. The cooling plate assembly has a pan member, first and second corrugated support members, a cover plate, and a thermally conductive layer. The pan member has first and second depressed plate portions. The first and second corrugated support members are disposed on the first and second depressed plate portions, respectively. The cover plate is coupled to the pan member such that the first and second corrugated support members are held between the cover plate and the pan member in first and second internal regions, respectively, defined by the cover plate and the pan member. The thermally conductive layer is disposed on the cover plate. The battery module is disposed on the thermally conductive layer.

Abstract: A battery system is provided. The battery system includes a cooling plate having a housing, an inlet port, and an outlet port. The housing defines an interior region. Both the inlet port and the outlet port fluidly communicate with the interior region. The battery system further includes a solid thermoplastic cooling fin having first and second panel portions. The first panel portion is disposed directly on and against the cooling plate. The battery system further includes a first battery cell disposed directly on and against a first side of the second panel portion of the solid thermoplastic cooling fin. The solid thermoplastic cooling fin is configured to conduct heat energy from the first battery cell to the cooling plate.

Abstract: A battery pack includes a battery pack housing defining an interior region with first and second interior spaces and an intermediate space. The battery pack housing includes inlet and outlet apertures communicating with the first and second interior spaces, respectively. The battery pack has a battery module disposed in the first interior space having a first battery cell and a heat exchanger. The heat exchanger defines a first flow path portion therethrough. The battery pack has a fan assembly disposed in the intermediate space having a first electric fan, and a thermally conductive housing disposed in the second interior space that defines a second flow path portion. The first electric fan urges air to flow through the inlet aperture, the first flow path portion, a portion of the first electric fan, the second flow path portion, and the outlet aperture.

Abstract: A battery pack having a cooling plate assembly and a battery module is provided. The cooling plate assembly has a pan member, first and second corrugated support members, a cover plate, and a thermally conductive layer. The pan member has first and second depressed plate portions. The first and second corrugated support members are disposed on the first and second depressed plate portions, respectively. The cover plate is coupled to the pan member such that the first and second corrugated support members are held between the cover plate and the pan member in first and second internal regions, respectively, defined by the cover plate and the pan member. The thermally conductive layer is disposed on the cover plate. The battery module is disposed on the thermally conductive layer.

Abstract: A battery cell assembly having a first battery cell and a cooling fin is provided. The first battery cell has a first housing and first and second electrical terminals. The cooling fin is disposed against the first housing. The cooling fin has a substantially rectangular-shaped plate that extends along a longitudinal axis. The substantially rectangular-shaped plate has a plate portion with a first side and a second side. The first side has a first plurality of recessed regions and a first plurality of flat regions. Each recessed region of the first plurality of recessed regions is disposed between two flat regions of the first plurality of flat regions along the longitudinal axis. The first housing of the first battery cell is disposed against the first side such that the first housing contacts the first plurality of flat regions.

Abstract: A battery module includes a first battery cell having a first housing and first and second electrical terminals. The first housing has first, second, third and fourth ends. The first and second electrical terminals extend outwardly from the third and fourth ends, respectively. A distance from the second end of the first housing to a second edge of the first electrical terminal is greater than a distance from the first end of the first housing to a first edge of the first electrical terminal. A distance from the second end of the first housing to a second edge of the second electrical terminal is greater than a distance from the first end of the first housing to a first edge of the second electrical terminal. The battery module further includes a cooling fin disposed adjacent to the first battery cell, and a cooling plate coupled to the cooling fin.

Abstract: A battery module having first and second battery cells is provided. The first battery cell has a housing and first and second electrical terminals. The housing extends longitudinally along a first axis and vertically along a second axis. The housing has first, second, third and fourth ends. The first and second ends extend parallel to the first axis. The third and fourth ends extend parallel to the second axis. The first electrical terminal extends from the third end in a direction parallel to the first axis, and has first and second edges extending parallel to the first axis. The first edge is disposed closer to the first end than the second edge of the first electrical terminal. A distance from the second end of the housing to the second edge of the first electrical terminal is greater than a distance from the first end of the housing to the first edge of the first electrical terminal.

Abstract: A battery module having first and second battery cells is provided. The first battery cell has a housing and first and second electrical terminals. The housing extends longitudinally along a first axis and vertically along a second axis. The housing has first, second, third and fourth ends. The first and second ends extend parallel to the first axis. The third and fourth ends extend parallel to the second axis. The first electrical terminal extends from the third end in a direction parallel to the first axis, and has first and second edges extending parallel to the first axis. The first edge is disposed closer to the first end than the second edge of the first electrical terminal. A distance from the second end of the housing to the second edge of the first electrical terminal is greater than a distance from the first end of the housing to the first edge of the first electrical terminal.

Abstract: A battery module includes a first battery cell having a first housing and first and second electrical terminals. The first housing has first, second, third and fourth ends. The first and second electrical terminals extend outwardly from the third and fourth ends, respectively. A distance from the second end of the first housing to a second edge of the first electrical terminal is greater than a distance from the first end of the first housing to a first edge of the first electrical terminal A distance from the second end of the first housing to a second edge of the second electrical terminal is greater than a distance from the first end of the first housing to a first edge of the second electrical terminal. The battery module further includes a cooling fin disposed adjacent to the first battery cell, and a cooling plate coupled to the cooling fin.

Abstract: A battery cell assembly having a first battery cell and a cooling fin is provided. The first battery cell has a first housing and first and second electrical terminals. The cooling fin is disposed against the first housing. The cooling fin has a substantially rectangular-shaped plate that extends along a longitudinal axis. The substantially rectangular-shaped plate has a plate portion with a first side and a second side. The first side has a first plurality of recessed regions and a first plurality of flat regions. Each recessed region of the first plurality of recessed regions is disposed between two flat regions of the first plurality of flat regions along the longitudinal axis. The first housing of the first battery cell is disposed against the first side such that the first housing contacts the first plurality of flat regions.

Abstract: A battery module having first and second battery cells is provided. The first battery cell has a housing and first and second electrical terminals. The housing extends longitudinally along a first axis and vertically along a second axis. The housing has first, second, third and fourth ends. The first and second ends extend parallel to the first axis. The third and fourth ends extend parallel to the second axis. The first electrical terminal extends from the third end in a direction parallel to the first axis, and has first and second edges extending parallel to the first axis. The first edge is disposed closer to the first end than the second edge of the first electrical terminal. A distance from the second end of the housing to the second edge of the first electrical terminal is greater than a distance from the first end of the housing to the first edge of the first electrical terminal.

Abstract: A battery module having first and second battery cells is provided. The first battery cell has a housing and first and second electrical terminals. The housing extends longitudinally along a first axis and vertically along a second axis. The housing has first, second, third and fourth ends. The first and second ends extend parallel to the first axis. The third and fourth ends extend parallel to the second axis. The first electrical terminal extends from the third end in a direction parallel to the first axis, and has first and second edges extending parallel to the first axis. The first edge is disposed closer to the first end than the second edge of the first electrical terminal. A distance from the second end of the housing to the second edge of the first electrical terminal is greater than a distance from the first end of the housing to the first edge of the first electrical terminal.

Abstract: A battery system is provided. The battery system includes a cooling plate having a housing, an inlet port, and an outlet port. The housing defines an interior region. Both the inlet port and the outlet port fluidly communicate with the interior region. The battery system further includes a solid thermoplastic cooling fin having first and second panel portions. The first panel portion is disposed directly on and against the cooling plate. The battery system further includes a first battery cell disposed directly on and against a first side of the second panel portion of the solid thermoplastic cooling fin. The solid thermoplastic cooling fin is configured to conduct heat energy from the first battery cell to the cooling plate.