Abstract: Retention assemblies are disclosed for retaining a battery cell stack/matrix relative to an enclosure tray on traction battery packs that include cell-to-pack battery systems. The retention assemblies may be positioned between a cell stack/cell matrix and an interior surface of the enclosure tray. The retention assemblies may include features such as slider panels, clips, adhesive, and/or shims designed for holding the cell stacks down at the cell stack-to-enclosure tray interface.

Abstract: Cover attachments are disclosed for securing an enclosure cover to a cell row/battery cell separator on traction battery packs that include cell-to-pack battery systems. One or more separators of a cell-to-pack battery system may be configured to separate cell stack rows or battery cells within the cell-to-pack battery system. A cover attachment (e.g., a clip, an adhesive puck, a magnet assembly, a hook and loop assembly, a ball-and-socket assembly, etc.) may connect to a portion of the separator for securing the enclosure cover directly to the cell-to-pack battery system. The combination of the cover attachments and the separators provides for enclosure cover retention at interior regions of the cell-to-pack battery system, maintains the enclosure cover at a spaced distance apart from the battery cells of the cell-to-pack battery system, and creates a desired amount of pack-level stiffness for distributing loads through the cell-to-pack battery system.

Abstract: A traction battery pack assembly includes first and second cell stacks each disposed along a cell stack axis and an enclosure assembly that encloses an interior area. The enclosure assembly has an enclosure structure that holds the first and second cell stacks within a cell-receiving area. The enclosure structure compresses the first cell stack along the cell stack axis of the first cell stack. The enclosure structure compresses the second cell stack along the cell stack axis of the second cell stack. The assembly further includes divider positioned between the first and second cell stacks. The divider partitions the interior area.

Abstract: A battery pack assembly method includes compressing a first cell stack, compressing a second cell stack, and inserting the first cell stack together with the second cell stack into a cell-receiving opening of an enclosure structure. Another traction battery pack assembly method includes simultaneously inserting a plurality of separate cell stacks into an enclosure structure when the plurality of cell stacks are each compressed by a compression fixture and, after the inserting, compressing the plurality of cell stacks using the enclosure structure.

Abstract: An electrochemical system having a thermal barrier layer is provided. The thermal barrier layer includes a polymer network having an inorganic portion and an organic portion such as silicone or a polysiloxane polymer network. The polymer network may further include filler component dispersed therein such as oxidized polyacrylonitrile milled fiber, Aerogel, hollow glass microspheres, and mica.

Abstract: A traction battery pack assembly includes, among other things, a foam section of a battery pack enclosure. The foam section provides a recessed area that at least partially receives a traction battery array. A substructure assembly is partially disposed within the foam section. An attachment point is provided by the substructure assembly. The attachment point is outside the foam section.

Abstract: A traction battery pack assembly includes, among other things, first and second pieces of an enclosure having an interior area. An attachment rim is disposed at a periphery of the first piece. The attachment rim has a stand-off that includes a platform portion and turned flange. The platform portion extends outward from the interior area in a first direction. The platform portion provides an aperture. The turned flange extends away from the platform portion in a second direction and terminates at an end face. The second direction is transverse to the first direction. The aperture is configured to receive a fastener that clamps the end face against the second piece.

Abstract: A traction battery assembly includes a thermal exchange device of a battery pack, and battery arrays disposed adjacent the thermal exchange device. A phase change material is secured to an area of the thermal exchange device. A method of managing thermal energy within a battery pack includes, among other things, positioning battery arrays against a thermal exchange device, and securing a phase change material to the thermal exchange device. The phase change material is configured to take on thermal energy from at least one of the battery arrays.

Abstract: A traction battery pack assembly includes, among other things, an enclosure having a lid and a tray. The enclosure has a corner area connecting a first side of the enclosure to a second side of the enclosure. The first side is transverse to the second side. The assembly further includes a patch secured to the corner area.

Abstract: An article, such as a battery pack system, includes a battery pack that is comprised of a plurality of battery cells. An external housing covers at least a portion of the battery pack. A silicate-based thermal barrier coating is configured to block heat emitted from the battery pack.

Abstract: This disclosure details exemplary traction battery pack designs for use in electrified vehicles. An exemplary traction battery pack may include a venting system having one or more vent exhaust channels. The vent exhaust channels may be integrated with an enclosure assembly of the battery pack for purging battery vent byproducts from the battery pack during cell venting events. In some embodiments, the vent exhaust channels are coated with a thermal protective coating for reducing heat dissipation to surrounding components.

Abstract: This disclosure relates to thermal event detection for battery packs of electrified vehicles. An example electrified vehicle includes a battery assembly including an enclosure assembly surrounding at least one battery array, and a controller configured to receive information associated with the battery assembly and detect a thermal event based on the information. The controller is configured to issue a plurality of corrective action commands following detection of the thermal event.

Abstract: Battery pack designs for use in electrified vehicles may include a polymer-based enclosure having features for sealing external joints, retaining components inside the battery pack, securing electrical and coolant lines to the polymer-based enclosure, etc. The proposed designs reduce the number of overall parts in assembly, such as fasteners and brackets, and simplify the overall battery pack manufacturing and assembly processes.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include a polymer-based enclosure assembly having features for both retaining components and transferring loads inside the battery pack. The battery packs may include one or more snap-in features for retaining the components and one or more foam spacers for separating adjacent battery arrays and establishing a load transfer path inside the battery pack.

Abstract: A traction battery pack assembly includes, among other things, a foam section of a battery pack enclosure. The foam section provides a recessed area that at least partially receives a traction battery array. A substructure assembly is partially disposed within the foam section. An attachment point is provided by the substructure assembly. The attachment point is outside the foam section.

Abstract: This disclosure relates to thermal event mitigation for battery packs of electrified vehicles. An example electrified vehicle includes a battery assembly with an enclosure assembly surrounding at least one battery array and a bag configured to selectively release nitrogen. The electrified vehicle further includes a controller configured to issue a plurality of corrective action commands in response to a detected thermal event. One of the corrective action commands includes instructing the bag to generate and release nitrogen within the enclosure assembly. Among other benefits, which will be appreciated from the below description, the disclosed arrangement promptly mitigates a thermal event of the battery assembly and takes additional corrective actions, such as providing various prompts and status indicators to the user.

Abstract: A battery pack includes a battery array and an enclosure assembly housing the battery array. The enclosure assembly includes a tray, a cover, and a mid-tray. A plurality of internal components are secured within the mid-tray to establish an electrical subassembly within the enclosure assembly.

Abstract: This disclosure relates to thermal event detection for battery packs of electrified vehicles. An example electrified vehicle includes a battery assembly including an enclosure assembly surrounding at least one battery array, and a controller configured to receive information associated with the battery assembly and detect a thermal event based on the information. The controller is configured to issue a plurality of corrective action commands following detection of the thermal event.

Abstract: This disclosure relates to thermal event mitigation for battery packs of electrified vehicles. An example electrified vehicle includes a battery assembly with an enclosure assembly surrounding at least one battery array and a bag configured to selectively release nitrogen. The electrified vehicle further includes a controller configured to issue a plurality of corrective action commands in response to a detected thermal event. One of the corrective action commands includes instructing the bag to generate and release nitrogen within the enclosure assembly. Among other benefits, which will be appreciated from the below description, the disclosed arrangement promptly mitigates a thermal event of the battery assembly and takes additional corrective actions, such as providing various prompts and status indicators to the user.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a battery system and a passive thermal suppression material system positioned about at least a portion of the battery system. The passive thermal suppression material system is configured to release a thermal suppression material during certain battery thermal events. The thermal suppression material prevents or delays thermal runaway inside the battery pack.