Abstract: Nestable cross-member beams are provided for use within traction battery packs. A first cross-member beam of a first cell stack may nest together with a second cross-member beam of a second cell stack to establish a structural cross-member assembly between the first and second cell stacks at a location inside the traction battery pack. The structural cross-member assembly may include one or more venting passageways that facilitate the venting of battery cell vent byproducts to a location external to the traction battery pack during battery thermal events. The venting passageways may direct the vent byproducts through one or more valve assemblies provided within an enclosure assembly of the traction battery pack. The valve assemblies may direct the vent byproducts through one or more vehicle body components.

Abstract: A method of assembling a battery pack includes, outside of a battery pack enclosure, securing at least one first battery cell to a first side of a thermal barrier, and securing at least one second battery cell to an opposite, second side of the thermal barrier. The method provides a battery cell subassembly with the thermal barrier sandwiched between the at least one first battery cell and the at least one second battery cell.

Abstract: Multifunctional cross-member beams are provided for use within traction battery packs. An exemplary cross-member beam may include features for interfacing with and supporting various subcomponents (e.g., battery cells, cell tab terminals, bus bars, thermal barriers, etc.) of a cell stack of the traction battery pack. The cross-member beam may further incorporate features for facilitating the venting of battery cell vent byproducts during battery thermal events.

Abstract: Cell stack end caps are provided for use within traction battery packs. An end cap may be positioned to at least partially fill a volume of space between a cell stack and an enclosure structure (e.g., an enclosure tray) inside the traction battery pack. The end cap may be configured to square a draft angle of a side wall of the enclosure structure in order to impart a compressive load to the cell stack and/or the enclosure structure. A foam structure may be positioned between the end cap and the enclosure structure or within a hollow passageway of the end cap for increasing the structural integrity of the traction battery pack.

Abstract: Divider fins are disclosed for traction battery packs. An exemplary divider fin may be arranged between adjacent battery cells of a battery cell stack. The divider fin may include an upper fin portion configured to interface with an enclosure cover, and a lower fin portion configured to interface with an enclosure tray or a heat exchange plate. The divider fin may be configured to compartmentalize the cell stack, structurally join upper and lower battery structures, contain thermal energy during battery thermal events, etc.

Abstract: A method includes electrically connecting a first battery cell to a second battery cell by joining a first tab terminal of the first battery cell to a second tab terminal of the second battery cell. The method further includes compressing the first tab terminal and the second tab terminal after the joining. A battery assembly includes a first tab terminal extending from a first housing of a first battery cell, and a second tab terminal extending from a second housing of a second battery cell. The second tab terminal is connected directly to the first tab terminal. The method further includes an insulating layer that encloses the first and second tab terminals against the first and second housings.

Abstract: A traction battery pack assembly includes a battery pack enclosure that provides an interior area, and at least one cell stack that includes battery cells and at least one divider distributed along a cell stack axis. The at least one divider compartmentalizes the interior area into a plurality of compartments. Each of the compartments holds at least one of the battery cells.

Abstract: A battery pack venting assembly includes a first beam establishing a first side of a passageway and a second beam establishing an opposite, second side of the passageway. The passageway is configured to communicate battery cell vent byproducts. A method of establishing a vent path within a traction battery pack includes, within an enclosure assembly of a battery pack, providing a cross-member assembly having a first beam and a second beam; and communicating battery cell vent byproducts through at least one opening in the first beam into a passageway having a perimeter that is at least partially provided by the first beam and the second beam.

Abstract: A battery pack terminal retention system includes a clasp configured to hold tab terminals as the tab terminals are electrically connected together. A battery pack terminal retention method includes holding terminals together using a clasp; and electrically connecting together the plurality of terminals during the holding. The terminals can be tab terminals that are electrically connected together using welds.

Abstract: A traction battery pack venting assembly includes an enclosure, at least one cell stack within the enclosure, a cross-member assembly within the enclosure, and a valve assembly that opens to provide a vent path from the at least one cell stack to a passageway of the cross-member assembly. A method of establishing a vent path within a traction battery pack includes, within a battery pack enclosure, using a valve assembly to block an opening to a passageway provided by a cross-member assembly; and in response to at least one battery cell within the battery pack enclosure venting, opening the valve assembly to permit flow through the opening to the passageway.

Abstract: An exemplary traction battery assembly includes, among other things, a battery pack and a securing assembly. The securing assembly secures the battery pack to a structure of the vehicle. The securing assembly is disposed along a horizontally facing side of the battery pack and is configured to move from a first position to a second position in response to a load to permit movement of the battery pack relative to the vehicle structure.

Abstract: A computer in a vehicle is programmed to receive sensor data about a vehicle occupant, select a category of behavior of the occupant based on the sensor data, and navigate to a predetermined location based on the selected category. The vehicle may be an autonomous vehicle that can be operated by the computer.

Abstract: This disclosure details electrified vehicles that are equipped with one or more attachment and sealing assemblies for securing a battery pack to vehicle body components. An exemplary attachment and sealing assembly may establish a mid-span attachment point of the battery pack. The attachment and sealing assembly may include an attachment column and a sealing ring that cooperate to secure the battery pack to the vehicle and to seal openings formed through the battery pack and the vehicle body component.

Abstract: This disclosure details electrified vehicles that are equipped with one or more attachment and sealing assemblies for securing a battery pack to the vehicle. An exemplary attachment and sealing assembly may establish a mid-span attachment point of the battery pack and may include a pass-through component, a fastener, and a seal. The fastener may be positioned relative to the pass-through component using either a bottom-up or top-down approach. The seal may radially seal between a portion of a battery pack enclosure assembly and the pass-through component.

Abstract: This disclosure details electrified vehicles that are equipped with one or more attachment and sealing assemblies for securing a battery pack to vehicle body components. An exemplary attachment and sealing assembly may establish a mid-span attachment point of the battery pack. The attachment and sealing assembly may include an attachment column and a sealing ring that cooperate to secure the battery pack to the vehicle and to seal openings formed through the battery pack and the vehicle body component.

Abstract: An exemplary method includes, among other things, providing first and second blanks that are nominally identical and that include an array of raised features. The method further includes removing a first combination of individual raised features from the first blank to provide a first battery component with a first flow path, and removing a different, second combination of individual raised features from the second blank to provide a second battery component with a different, second flow path. An exemplary battery assembly includes, among other things, a blank having a plurality of ribs extending from a floor. The blank is configured such that a first combination of the ribs are removable from the blank to provide a first battery component having first flow path, and a different, second combination of the ribs are removable from the blank to provide a second battery component having a different, second flow path.

Abstract: An autonomous vehicle includes interior sensors including a camera, IR camera, electro-chemical sensor, humidity sensor, and temperature sensor. Initial and final outputs of these sensors are captured for a trip conveying one or more passengers. If changes in the outputs of the sensors are detected, whether the final outputs of the sensors are acceptable may be evaluated. In some embodiments, an aggregation of the outputs is evaluated and found unacceptable even where individual outputs are acceptable. Outputs may be presented to a dispatcher to confirm that the outputs are unacceptable. If the outputs are found to be unacceptable, the vehicle may be autonomously driven to a cleaning station. Personal items may be identified in camera outputs and alerts generated in response.

Abstract: An exemplary battery assembly includes first and second pieces of an enclosure, a flange of the first piece, and a clamping device compressing together the flange and a portion of the second piece to seal an interface. The clamping device has an interior area that receives the flange such that the clamping device extends continuously from a first side, about an outer edge, to an opposite, second side of the flange. An exemplary battery enclosure securing method includes receiving a flange of a first enclosure piece within an open area of a clamping device while the clamping device compresses together the flange and a portion of a second enclosure piece. The clamping device extends continuously from a first side of the flange, about an outer edge of the flange, to an opposite, second side of the flange when the flange is received within the open area.

Abstract: A charge system includes a base, a platform including a projecting plug, at least three interlinked legs, and a first and second sets of articulating joints. The at least three interlinked legs are of a fixed same length and are mechanically biased to be perpendicular to the base. The first and second sets of articulating joints respectively connect opposite ends of the legs with the platform and base such that, responsive to a force on the plug, the legs tilt while remaining parallel to each other and the platform remains parallel with the base.

Abstract: A hybrid electric vehicle having one or more controllers, at least two axles independently driven by respective electric machines (EMs) that are each coupled to a separate battery, and a combustion engine (CE) coupled to one of the axles. At least one of the controller(s) are configured to deliver power to one of the axles in a single axle drive mode, and in response to a torque demand signal (TDS) exceeding a single axle power limit, to deliver power to another axle, and/or all axles. The controller(s) are further configured to respond to the TDS exceeding a multiple axle power limit, and to deliver additional CE power to the coupled axle. In response to a braking signal, the controller(s) may also adjust at least one of the EMs to capture mechanical braking energy from a respective axle, and generate negative torque to charge one or more of the separate batteries.