Abstract: Thermal barrier systems are provided for use within traction battery packs. An exemplary thermal barrier system may include one or more expandable gap fillers configured to transition from a compressed state to an uncompressed state when a temperature near the expandable gap filler exceeds a predefined temperature threshold. In the uncompressed state, the expandable gap filler reduces a free air volume of a void space of the traction battery pack, thereby managing or even preventing the transfer of thermal energy to nearby structures.

Abstract: A battery pack assembly method includes compressing at least one cell stack, inserting the at least one cell stack into a cell-receiving opening of an enclosure structure, and pushing at least one cell of the at least one cell stack out of the enclosure structure using a pusher. Another traction battery pack assembly method includes moving a cell stack into an enclosure structure from a compression fixture that compresses the cell stack. The cell stack includes a plurality of battery cells. After the moving, the method compresses the cell stack using the enclosure structure. The method then includes establishing electrical connections between the battery cells of the cell stack, and testing the electrical connections prior to securing a busbar to the cell stack.

Abstract: Thermal barrier assemblies are provided for inhibiting the transfer of thermal energy inside a traction battery pack while simultaneously accommodating battery cell swelling forces and providing sufficient structural stiffness. An exemplary thermal barrier assembly may include a structural barrier, a thermal insulation medium, and one or more flexible structures that are arranged to contain the thermal insulation medium within an outer perimeter provided by the structural barrier. The flexible structures may be configured as flexible links or film layers that are capable of mechanically isolating a first portion of the structural barrier that contacts a battery cell undergoing swelling from a second portion of the structural barrier that is not in contact with the battery cell, thereby providing uniform resistance to the battery cell swelling forces while also providing structural stiffness.

Abstract: A method of assembling a battery pack includes inserting a guide within a slot of a slotted assembly; guiding one or more terminals into the slot using the guide; and withdrawing the guide from the slot while the one or more terminals remain in the slot. A traction battery pack assembly includes a terminal guide; and an actuator assembly that rotates the terminal guide back and forth between a guiding position and a withdrawn position. The terminal guide is at least partially disposed within a slot of a slotted assembly when in the guiding position such that the terminal guide can guide insertion of one or more terminals into the slot. The terminal guide is withdrawn from the slot when in the withdrawn position.

Abstract: A battery assembly includes at least one enclosure structure that is thermoformed about a battery assembly of a battery pack. A method of enclosing a battery assembly can include placing a sheet of material adjacent a battery assembly of a battery pack; and thermoforming the sheet of material about the battery assembly to provide an enclosure structure for the battery assembly.

Abstract: A structural assembly for an electric vehicle that includes a vehicle frame and a battery structure. The vehicle frame is distinct from a vehicle body. The vehicle frame includes a first section and a second section. The first section includes opposed longitudinal rails. The battery structure is configured to house power storage units and is disposed between the opposed longitudinal rails. The battery structure includes a battery housing that is secured to the opposed longitudinal rails of the first section. The first section and the battery housing are combined into a unitized structure that is removably secured to the second section of the vehicle frame.

Abstract: Traction battery packs are disclosed that include cell-to-pack battery systems. A cell stack/cell matrix of the cell-to-pack battery system may be positioned within an irregularly shaped enclosure tray of the traction battery pack. A block insert may be positioned at an interface between the cell stack/cell matrix and an irregularly shaped interior surface of the enclosure tray. The block insert may be configured to facilitate insertion of the cell stack/cell matrix into the enclosure tray, transfer compression loads from the enclosure tray walls to the cell stack/cell matrix, resist battery cell compression loads, etc.

Abstract: A structural assembly for an electric vehicle includes a vehicle frame and a battery structure. The vehicle frame is distinct from a vehicle body and includes a front section, a rear section and a mid-section disposed between the front and rear sections. The mid-section includes opposed longitudinal rails. The battery structure is configured to house power storage units and is disposed between the opposed longitudinal rails. The battery structure includes a battery housing secured to the opposed longitudinal rails of the mid-section. The mid-section and the battery housing are combined into a unitized structure that is removably secured to the front and rear sections of the vehicle frame.

Abstract: Manufacturing processes are disclosed for assembling traction battery packs that include battery systems, such as cell-to-pack battery systems. An exemplary assembly method includes inserting one or more cell stacks of the cell-to-pack battery system into a cell-compressing opening of an enclosure tray. The method may involve the use of slider plates that provide sliding surfaces that facilitate the insertion of the cell stacks into the cell compressing opening.

Abstract: Integrated filtering systems are provided for filtering battery vent byproducts (e.g., gases and/or effluent particulates) during battery thermal events of a traction battery pack. The filtering systems may include one or more filters integrated as part of a vent valve, a vent pipe, a pressure equalization device, and/or an array housing of the traction battery pack, and/or as part of a structure that is separate from the traction battery pack. The filter may be configured to filter a constituent element (e.g., carbon monoxide (CO), hydrogen fluoride (HF), etc.) of a gaseous mixture vented from a battery cell of the traction battery pack during a battery thermal event, thereby mitigating the potential for vent gas combustion. The filter may be further configured to control the escape of particulates to surrounding environments.

Abstract: A traction battery assembly includes a busbar, a carrier frame having a pocket that receives the busbar, and a cap secured to the carrier frame to contain the busbar within the pocket. A busbar retention method includes positioning at least one busbar with a pocket of a carrier frame and resting the busbar on at least one ledge and securing a cap to the carrier frame to hold the at least one busbar within the pocket.

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 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: A battery pack includes an upper sidewall section of an enclosure, a lower sidewall section of the enclosure, and a fastener that moves to a secured position to secure the upper sidewall section to the lower sidewall section. The fastener is configured to be moved to the secured position from within an interior area of the enclosure. The battery pack further includes a gasket seal held between the upper sidewall section and the lower sidewall section at a position outside the fastener relative to an interior area of the enclosure.

Abstract: A structural assembly for an electric vehicle includes a vehicle frame and a battery structure. The vehicle frame is distinct from a vehicle body and includes a front section, a rear section and a mid-section disposed between the front and rear sections. The mid-section includes opposed longitudinal rails. The battery structure is configured to house power storage units and is disposed between the opposed longitudinal rails. The battery structure includes a battery housing secured to the opposed longitudinal rails of the mid-section. The mid-section and the battery housing are combined into a unitized structure that is removably secured to the front and rear sections of the vehicle frame.

Abstract: A structural assembly for an electric vehicle includes a vehicle frame, a battery structure, a pair of mounting structures, and a plurality of fasteners. The vehicle frame includes opposed longitudinal rails. The battery structure is disposed between the opposed longitudinal rails and includes a battery housing configured to house power storage units. Each mounting structure is secured to a respective side of the battery housing and supports a corresponding longitudinal rail. The plurality of fasteners extend through a corresponding mounting structure of the pair of mounting structures and a corresponding longitudinal rail of the opposed longitudinal rails to secure the vehicle frame and the battery structure to each other. An outer periphery of the corresponding mounting structure is substantially flush with an outer periphery of the corresponding longitudinal rail.

Abstract: A battery pack support system includes a rocker assembly that has a body portion and a pack portion. The pack portion is secured to the body portion to connect a battery pack to a vehicle. The pack portion configured to compress a plurality of battery cells within the battery pack.

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: 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 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.