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 battery pack includes a heat exchanger plate having a first attachment feature and a battery assembly having a second attachment feature configured to engage the first attachment feature as the battery assembly is moved against the heat exchanger plate to thermally couple the battery assembly to the heat exchanger plate.

Abstract: A method according to an exemplary aspect of the present disclosure includes, among other things, compressing a cell stack, which itself includes at least one battery cell and a support plate spaced-apart from an upper surface of the cell(s). The method further includes inserting the cell stack into a pocket of a structural assembly by applying a force to the support plate. A battery assembly is also disclosed.

Abstract: An exemplary battery assembly includes a shield having a floor and walls extending transversely away from the floor. The shield provides a cavity configured to receive a battery pack of an electrified vehicle. The cavity is larger than the traction battery pack so that there is a gap between at least some of the walls and the traction battery pack within the cavity. An exemplary shielding method includes securing a shield to a vehicle frame to enclose a traction battery pack held within a cavity of the shield.

Abstract: A motor vehicle according to an exemplary aspect of the present disclosure includes, among other things, a frame including a rail and an electrical distribution system routed at least partially through the rail. A method is also disclosed.

Abstract: An exemplary battery thermal management assembly includes a first structure having a first material composition, and a second structure having a different, second material composition. The second structure is configured to exchange thermal energy between a battery array and a fluid communicated through a fluid channel that is bounded by the first and second structures. An exemplary battery thermal management method includes securing a first structure of a first material composition relative to a second structure of a different, second material composition to provide a fluid channel. The method further includes using the second structure to pass thermal energy between a battery and a fluid within the fluid channel.

Abstract: An exemplary battery pack assembly includes an enclosure having a plurality of horizontally facing sides extending between a first and a second vertically facing side to provide an interior, a component within the interior, and a pocket of the first vertically facing side. The pocket is vertically recessed such that a pocket floor of the pocket is vertically aligned with a portion of the component.

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 battery pack includes a first side oriented battery assembly, a second side oriented battery assembly, and a vent chamber arranged between the first side oriented battery assembly and the second side oriented battery assembly. The first and second side oriented battery assemblies are thus arranged to share a common vent chamber. One of the first and second side oriented battery assemblies may additionally share a common heat exchanger device with a third side oriented battery assembly.

Abstract: An exemplary battery assembly includes, among other things, an enclosure defining an interior, and a frame disposed within a wall of the enclosure. The frame includes at least one retention feature configured to hold a service panel in a position where the service panel covers an opening to the interior. An exemplary method includes, among other things, transitioning a service panel to an engaged position with at least one retention feature to secure the service panel in a position where the service panel covers an opening in an enclosure. The at least one retention feature is provided by a frame disposed within a wall of the 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.

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: An exemplary method of securing battery cells of a battery pack includes limiting upward movement of a separator by blocking movement of a projection with a structure. The projection extends from a spacer section of the separator and has a hook shape with an upwardly extending portion outside the structure. The method further includes limiting upward movement of a battery cell using the separator. Another exemplary method of securing battery cells of a battery pack includes limiting movement of a separator in a direction by blocking movement of a projection in the direction. The projection extends from a spacer section of the separator. The projection has a hook shape with a portion extending in the direction. The spacer section and the portion are on opposite sides of a structure. The method further includes limiting movement of a battery cell in the direction using the separator.

Abstract: A hybrid energy storage and delivery device includes a plastic enclosure that establishes a first sealed chamber and a second sealed chamber. The first sealed chamber is configured as a fuel tank for storing a liquid fuel and the second sealed chamber is configured as a battery pack for storing electrical energy. Thus, the fuel tank and battery pack may be integrated together within a single enclosure in order to improve vehicle packaging efficiencies.

Abstract: A battery pack according to an exemplary aspect of the present disclosure includes, among other things, an enclosure that houses at least one battery cell and a vent device comprised of a polymeric material and adapted to discharge battery vent byproducts vented by the battery cell to a location external to the enclosure while preventing ingress of environmental fluids into the enclosure.

Abstract: A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, an enclosure assembly defining an interior and a service panel integrally formed in the enclosure assembly. The service panel includes a ductile portion that is removable to access the interior.

Abstract: An exemplary traction battery retention assembly includes an attachment feature formed with a portion of an enclosure that houses a battery array. The attachment feature is sized such that a portion of the attachment feature can be received within an attachment feature of the battery array to hold the battery array within the enclosure. Another exemplary traction battery retention assembly includes a projection from an outer wall of a battery array. An attachment feature is formed with a portion of an enclosure that houses the battery array and includes an overhang surface to a surface of the projection to hold the array relative to the enclosure. Yet another traction battery pack assembly includes an enclosure of a battery pack that is formed together with a rib having sides extending to an end face. The rib extends to a structure housed within the enclosure.

Abstract: A battery assembly includes a plurality of battery cells and a support structure positioned about the plurality of battery cells. The support structure includes at least one sidewall and the at least one sidewall includes a first flange that extends adjacent a top surface of each of the plurality of battery cells and a second flange that extends beyond a bottom surface of each of the plurality of battery cells.

Abstract: An exemplary thermal interface material installation method includes, among other things, moving a material through a conduit to a cavity within a battery array. The conduit is at least partially provided by a thermal exchange plate of the battery array. The method further includes holding the material within the cavity to provide a thermal interface material between the thermal exchange plate and at least one battery cell assembly. An exemplary battery thermal interface material installation assembly includes a thermal exchange plate including a conduit with at least one inlet that opens to an exterior of a battery array, and at least one outlet that opens to a cavity between the thermal exchange plate and a plurality of battery cell assemblies.

Abstract: A battery system includes a first battery module, a second battery module, a supply line, a return line, and a film heater. The supply and return lines are configured to circulate a heat transfer medium in response to a first temperature condition, and the film heat is configured to heat the first battery module and the second battery module in response to a second temperature condition.