Abstract: A battery, such as a traction battery for an electrified vehicle (EV), includes a battery sensor, such as a battery pack sensing module (BPSM), arranged internally within a housing of the battery. The battery further includes one or more battery cell arrays arranged within the housing. Each battery cell array including battery cells and a printed circuit board (PCB) electrically connected with voltage sense leads associated with the battery cells. The battery further includes a primary PCB arranged within the housing and electrically connected to the battery cell array PCBs. The battery sensor is electrically connected to the primary PCB to establish an electrical connection with the battery cell array PCBs whereby the battery sensor can sense the voltages of the battery cells.

Abstract: A structural assembly for a battery structure of a vehicle includes a lower wall and a pair of cross members. The lower wall is configured to support a cell stack. The pair of cross members are spaced apart from each other in a longitudinal direction of the vehicle. Each cross member provides lateral support for a respective side of the cell stack and is configured to extend substantially an entire width of a battery enclosure. Each cross member of the pair of cross members includes an outer wall, an inner wall spaced apart from the outer wall, and connecting members. The outer wall, the inner wall, and connecting members cooperate with each other to define an internal cavity. The inner walls of the pair of cross members are secured to the lower wall and slidable relative to the outer walls of the pair of cross members.

Abstract: A structural assembly for a battery structure includes a lower wall and a pair of cross members. The lower wall is configured to support a cell stack. The cross members are spaced apart from each other in a longitudinal direction of a vehicle. Each cross member supports a respective side of the cell stack and is configured to extend substantially an entire width of the battery structure. Each cross member includes an outer wall, an inner wall, and connecting members that connect the outer wall to the inner wall. The outer wall, the inner wall, and the connecting members cooperate to define an internal cavity. The inner walls of the cross members are secured to the lower wall to form a unitized structure that houses the cell stack.

Abstract: A structural assembly for a battery structure includes a first shell, a second shell and a cold plate. The first shell includes a first cross member portion providing lateral support for a respective side of a cell stack. The second shell is secured to the first shell to define a unitized structure that houses the cell stack. The second shell includes a second cross member portion providing lateral support for a respective side of the cell stack and is spaced apart along a longitudinal direction of the vehicle relative to the first cross member portion. The cold plate is housed within the unitized structure. Each of the first and second cross member portions includes an outer wall, an inner wall spaced apart from the outer wall, and connecting members that connect the outer wall to the inner wall.

Abstract: An assembly includes a busbar of a traction battery pack, and at least one terminal of a battery cell of the traction battery pack. The at least one terminal is electrically coupled to the busbar. The assembly further includes a thermal exchange plate, and a thermal interface material that communicates thermal energy to the thermal exchange plate from the at least one terminal, from the busbar, or both.

Abstract: A battery pack sensing module includes a rigid printed circuit board that is to be carried by and bridge between a pair of battery cell arrays, a plurality of integrated circuits mounted on the rigid printed circuit board, and a pair of sense lead connectors at opposite ends of the rigid printed circuit board. Each of the sense lead connectors is electrically connected with at least one of the integrated circuits and can mate with a receiving connector of one of the battery cell arrays to establish an electrical connection between the receiving connector and the at least one of the integrated circuits.

Abstract: A service tool assembly according to an exemplary aspect of the present disclosure includes, among other things, a service tool that extends through an access hole in a floor of an electrified vehicle and is adapted to engage a threaded hole of a battery pack. The service tool is rotatable to translate the battery pack relative to the electrified vehicle.

Abstract: A traction battery assembly includes an array housing that houses battery cells, and a filter layer permitting a flow of gas vented from at least one of the battery cells to an area outside the array housing. The filter layer blocks a flow of particulates vented from the at least one battery cell to the area outside the array housing.

Abstract: Battery arrays may be housed within electrified vehicle battery packs. An exemplary battery array may include an array support structure that includes a roll bonded cold plate. The roll bonded cold plate may be integrated into the battery array, as opposed to an outer enclosure assembly of the traction battery pack, and is thus arranged to directly thermally manage one or more battery cells of the battery array. The roll bonded cold plate may be configured to establish a single side or multiple sides of the array support structure.

Abstract: Exemplary bus bar assemblies may be used to electrically couple adjacent components of electrified vehicle traction battery packs, for example. An exemplary bus bar assembly includes a flexible braided design that may be packaged out of position and secured via a clip for shipping and handling and then folded into a position suitable for traction battery pack component assembly. Another exemplary bus bar assembly includes a semi-rigid design having tight tolerances and reliefs designed into the part to allow for fastening two adjacent traction battery pack components in a specific order to allow for component overlapping.