Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a battery system and an expandable polymer foam enclosure that substantially encapsulates the battery system. An expandable polymer foam may be introduced into a mold, expand, and then cure around to battery system to form the enclosure.

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 thermally managing internal components of the battery pack. In some embodiments, the enclosure assembly may include molded-in fluid channels or molded-in tubing for establishing a cooling circuit of the battery pack. In other embodiments, the enclosure assembly may include molded-in channels that receive tubing for establishing a cooling circuit of the battery pack.

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: An exemplary battery assembly includes, among other things, a battery array, and an expanded polymer-based enclosure that at least partially surrounds the battery array. The expanded polymer-based enclosure includes a vent manifold to communicate gases vented from the battery array. An exemplary method includes, among other things, forming a vent manifold within a polymer-based enclosure. The vent manifold is to communicate gases vented from a battery array. The method further includes at least partially surrounding the battery array with the polymer-based enclosure.

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.