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: Structural cross-member assemblies are provided for traction battery packs. An exemplary cross-member assembly may include a cross-member beam having a beam body and at least one reinforcement section that provides structural integrity to the beam body. The reinforcement section may be a pultrusion and may embody various cross-sectional shapes. The cross-member beam may be positioned adjacent to an additional cross-member beam to establish the cross-member assembly disposed between adjacent cell stacks of the traction battery pack.

Abstract: An electrical connection system includes a first electrical contact, and a second electrical contact joined directly to the first electrical contact. The first electrical contact is configured to flex relative to the second electrical contact along a first axis, and configured to flex relative to the first electrical contact along a second axis.

Abstract: A battery pack system includes a first tab terminal, a second tab terminal joined to the first tab terminal, and at least one point spaced a distance from the first and second tab terminals. The at least one point is configured to pierce at least the first tab terminal when the first tab terminal and the at least one point are shifted relative to each other such that the at least one point contacts the first tab terminal.

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 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 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: 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 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: 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 positioning at least one first battery cell having tab terminals adjacent to at least one second battery cell having tab terminals to provide a battery cell subassembly. The tab terminals of the at least one first battery cell and the at least one second battery cell are connected on a first side of the battery cell subassembly. The tab terminals of the at least one first battery cell and the at least one second battery cell are disconnected on an opposite, second side of the battery cell subassembly. After he positioning, the method includes inserting the tab terminals that are disconnected through at least one aperture in a cross-member.

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: 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: Methods and systems are provided for a battery cooling enclosure. In one embodiment, the battery cooling enclosure may be incorporated in an electric vehicle and may comprise battery cooling system, including a first support rail with a first coolant inlet, a second support rail with a first coolant outlet, and a plurality of cold plate slots arranged in parallel between the first support rail and the second support rail. Each slot of the plurality of cold plate slots is coupled to a first fluid passage of the first support rail and a second fluid passage of the second support rail. The battery cooling system of the battery cooling enclosure may thus allow for cooling of a battery using a variable amount of cold plates.

Abstract: A battery housing for a traction battery. The battery housing includes a first housing shell, and a second housing shell which can be connected to the first housing shell, for bounding an interior formed to receive at least one battery module. The first housing shell has a first collar which runs at least partially around the first housing shell. The second housing shell has a second collar which runs at least partially around the second housing shell. The battery housing has at least one connection element having two pressure limbs. The at least one connection element engages around the first collar and the second collar and to clamp by the two pressure limbs of the connection element exerting a normal force on the first collar and on the second collar. The first collar and/or the second collar has at least one first latching means. The connection element has at least one second latching means.

Abstract: Multi-piece enclosure covers are disclosed for use on traction battery packs that include cell-to-pack battery systems. An exemplary multi-piece enclosure cover may include a plurality of individually removable cover panels. The cover panels may be positioned in a shingled or overlapping fashion relative to one another for covering the cell-to-pack battery system. Each cover panel may be individually removed relative to the remaining cover panels of the enclosure cover for servicing one or more battery internal components of the traction battery pack. The unremoved cover panels may support a portion of the tensile loads acting upon an enclosure tray of the traction battery pack while another cover panel is removed.

Abstract: A traction battery pack for an electrified vehicle may include a protection bracket for shielding a vent feature of the traction battery pack. An exemplary protection bracket may be made of a polymeric material and is designed to shield the vent feature from debris impingement. The protection bracket may include features such as a mesh venting pattern and a melting point that is lower than the temperature of battery vent byproducts that may be released during battery thermal events of the traction battery pack.

Abstract: Traction battery packs are disclosed that include battery systems. A cell stack/cell matrix of the battery system may be positioned within an enclosure tray of the traction battery pack. A wedge insert may be positioned at an interface between the cell stack/cell matrix and a side wall of the enclosure tray. The side wall may include a draft angle. The wedge insert may be configured to translate the draft angle in order to apply a compressive load in a direction that is substantially normal to the cell stack/cell matrix.