Abstract: A battery pack assembly includes an enclosure assembly having an interior area, first and second cell stacks within the interior area, and a support assembly disposed between the first and second cell stacks within the interior area. The support assembly is configured to redirect a coolant that has been communicated over the first cell stack before the coolant is communicated over the second cell stack.

Abstract: Sealed busbar assemblies are provided for use within traction battery packs. An exemplary sealed busbar assembly may be configured to electrically connect a first battery array and a second battery array of the traction battery pack. Primary seals and secondary seals of the sealed busbar assembly may cooperate to seal high voltage connections relative to both the first battery array and the second battery array. The high voltage connections may be established by the busbar, a pair of fasteners, and high voltage array busbars of both the first battery array and the second battery array.

Abstract: Array housing designs are disclosed for battery arrays of a traction battery pack. An exemplary battery array may include an array housing having a ribbed structure that includes at least one rib (e.g., external and/or internal) configured for increasing the structural stiffness of the battery array. A groove may extend at least partially through the rib, and an adhesive/sealant may be disposed within the groove for securing a surrounding structure relative to the array housing and thereby structurally integrating the battery array. In some implementations, the groove may receive a fin of a thermal barrier assembly of a battery cell stack of the battery array.

Abstract: An automotive battery system for electrified vehicles is presented. The system includes a traction battery with arrays submerged in cooling fluid, and a pump circulating the fluid. The pump includes circuitry configured to detect current flow through the cooling fluid from the traction battery to the circuitry, indicating fluid contamination or isolation faults. This circuitry may be coupled with either high or low voltage pumps. A battery management system receives data from the circuitry, reports contamination levels, and may trigger responses including disabling arrays or adjusting charging rates.

Abstract: An electrified vehicle system is presented. The electrified vehicle system has a traction battery incorporating a plurality of electrically connected array modules submerged in a cooling fluid. A sensing component, coupled with at least one array module and immersed in the cooling fluid, is configured to detect a voltage drop when the fluid's contamination level reaches a threshold, thereby increasing electrical conductivity. This sensed voltage drop is communicated to a traction battery monitoring system, enabling proactive management of cooling fluid integrity.

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: A device may include a thermal barrier assembly arranged between a first battery cell and a second battery cell. A device may include a thermal insulating layer of the thermal barrier assembly configured to reduce thermal energy transfer between the first battery cell and the second battery cell. A device may include a first heat spreader fin and a second heat spreader fin each configured to establish a path for directing thermal energy from the first battery cell or the second battery cell away from the thermal insulating layer.

Abstract: This disclosure relates generally to battery packs for electrified vehicles, and in particular relates to a volume filler for immersion cooled battery arrays. In some aspects, the techniques described herein relate to a battery pack, including: an enclosure assembly defining a volume; a battery array within the volume, wherein the battery array includes a plurality of battery cells; and a volume filler within the volume, wherein the volume filler is disposed on a side of the battery array.

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. 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.

Abstract: Battery arrays are provided for traction battery packs. An exemplary battery array may include a multi-layered busbar assembly having at least a first busbar layer and a second busbar layer. Battery cell tab terminals may be trapped between the first busbar layer and the second busbar layer of the busbar assembly. The battery cell tab terminals, the first busbar layer, and the second busbar layer may then be fused together, such as by one or more welds, to electrically connect a grouping of battery cells of the array.

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: Battery arrays are provided for traction battery packs. An exemplary battery array may include a thermal barrier foam system that includes one or more foam blocks arranged to fill void spaces within the battery array to mitigate cell-to-cell and/or array-to-array thermal propagation. The foam blocks may be secured to hook structures of a bus bar module of the battery array. The hook structures can be integrated as part of the bus bar module or part of a separate structure that is attachable to the bus bar module.

Abstract: Battery arrays are provided for traction battery packs. An exemplary battery array may include a first cell stack subassembly including a first split dividing wall member, and a second cell stack subassembly including a second split dividing wall member. The first split dividing wall member and the second split dividing wall member cooperate to establish a dividing wall assembly between the first cell stack subassembly and the second cell stack subassembly. The dividing wall assembly can function to both provide the necessary tensile structure for maintaining battery cell compression and thermally isolate the adjacent cell stack subassemblies from one another.

Abstract: Battery arrays are provided for traction battery packs. An exemplary battery array may include one or more access ports for guiding a measurement probe of a testing device directly to an internal component (e.g., a bus bar) of the battery array. The testing device may then be utilized to measure a property (e.g., voltage, resistance, current, temperature, etc.) associated with the internal component without the need to first disassemble the battery array.

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 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 traction battery pack includes a cell stack, an enclosure assembly housing the cell stack, and stand-offs that space-apart the cell stack from a portion of the enclosure assembly to provide a coolant channel configured to communicate a coolant. The stand-offs can be part of the enclosure assembly or part of an insert separate from the enclosure assembly.

Abstract: An electrical connection system for a traction battery pack includes a first battery array, a second battery array, and a plug-and-socket coupler that electrically connects the first battery array to the second battery array when in an engaged position. A method of electrically connecting battery arrays of a traction battery includes electrically connecting a first battery array to a second battery array by moving the first battery array relative to the second battery array.

Abstract: This disclosure relates generally to battery packs for electrified vehicles, and in particular relates to a battery pack including a busbar frame configured as a coolant manifold. In some aspects, the techniques described herein relate to a battery pack, including: a battery array, wherein the battery array includes a plurality of battery cells and at least one busbar; and a busbar frame configured to support the at least one busbar, wherein the busbar frame includes an internal channel configured to communicate a fluid to thermally condition the battery array.

Abstract: This disclosure relates generally to battery packs for electrified vehicles, and in particular relates to thermal exchange plates for immersion cooled battery arrays. In some aspects, the techniques described herein relate to a battery pack, including: a battery array including a plurality of battery cells, wherein the plurality of battery cells includes a first battery cell and a second battery cell; and a thermal exchange plate, wherein the first battery cell is spaced-apart from the second battery cell by the thermal exchange plate, wherein the thermal exchange plate includes a main section and a projection extending outward from the main section, wherein the projection includes a channel configured to communicate a fluid to thermally condition the battery array.