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: 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 frame lit mirror component includes an extruded frame member. The extruded frame member further includes a mirror mounting edge. The mirror mounting edge extends along a longitudinal direction of the extruded frame member. The mirror mounting edge is sized to receive an edge of a mirror. A light source volume extends along the longitudinal direction of the extruded frame member. An angle exists between the mirror mounting edge and the light source volume. The light source volume is sized to receive a light source, such that when the light source is in an on-state light radiates from the light source volume.

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: A transmission assembly includes a cavity in a female U-joint having a groove that extends radially outward from an inner diameter thereof and bounded by three planar drive surfaces. A male U-joint member includes a drive end includes a longitudinal rectangular extension protruding radially outward from a periphery and positioned within the groove of the cavity. The drive end includes a longitudinal rectangular insert has a portion forming the extension positioned within the groove and retained within the drive end. The extension includes (1) opposing longitudinal sides, each forming a side crest disposed between a pair of angular side surfaces that extend axially from the side crest inward toward a center of the extension, and (2) a top side forming a top crest disposed between a pair of angular top surfaces that extend axially from the top crest downward toward the center of the extension.

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: 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.

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: Battery cell grouping solutions are disclosed for assembling traction battery packs that include cell-to-pack battery systems. A cell grouping assembly may be utilized to establish a common datum reference plane relative to multiple groupings of battery cells. An exemplary assembly method may include positioning the groupings of battery cells relative to the cell grouping assembly, and then applying a compressive force to the groupings of battery cells to provide cell stacks of the cell-to-pack battery system. The grouped cell stacks may then be located to an enclosure tray of the traction battery pack.

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 pack includes a cell-to-pack battery system. A selectable shim system may be used to augment a compressive load applied to one or more cell stacks of the cell-to-pack battery system. A method of assembling the traction battery pack may include measuring a first dimension associated with each cell stack of the cell-to-pack battery system, measuring a second dimension associated with an enclosure tray, and selecting an appropriately sized shim of the selectable shim system for applying a desired amount of compression to the battery cells of each cell stack when the cell stack is received within the enclosure tray.

Abstract: Manufacturing processes are disclosed for assembling traction battery packs that include cell-to-pack battery systems. An exemplary assembly method includes inserting a cell matrix of the cell-to-pack battery system into a cell-compressing opening of an enclosure tray using a top-down approach. The method may include compressing a plurality of cell stacks to a desired length, compressing the cell stacks together in a transverse direction to form the cell matrix, and then installing the cell matrix as a single unit into the cell-compressing opening of the enclosure tray.

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: 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 battery pack assembly method, including: positioning at least one cell stack within an enclosure structure; moving a compressing wall against the at least one cell stack to a position where the compressing wall applies a compressive force to the at least one cell stack between the enclosure structure and the compressing wall; and securing the compressing wall to hold the at least one cell stack in the position.

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 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: 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: Cell row separators are disclosed for use within traction battery packs that include cell-to-pack battery systems. An exemplary cell-to-pack battery system may include a first cell stack, a second cell stack, and a cell row separator secured to both the first cell stack and the second cell stack. The separator is adapted for structurally coupling the first cell stack and the second cell stack together.

Abstract: A traction battery pack assembly includes battery cells, an enclosure tray, an enclosure cover that is secured to enclosure tray to provide an interior area that houses the plurality of battery cells, and an electronics support plate supported by the enclosure cover. A traction battery electronics support method includes positioning battery cells of a traction battery pack within an enclosure tray of the traction battery pack, connecting at least one electronics module electrically to other components of the traction battery pack. After the connecting, the method includes securing an electronics support plate to an enclosure cover of the traction battery pack. The electronics support plate supports the at least one electronics module.