Abstract: A traction battery pack assembly includes an enclosure assembly configured to house a plurality of battery cells within an interior area. The enclosure assembly is at least partially provided by a multilayer structure having an apertured core with one or more layers sandwiched between an outer shell and an inner shell. The apertured core has a plurality of apertures. The multilayer structure is at least partially impregnated with a resin.

Abstract: A battery pack venting system includes one or more cell stacks of a traction battery pack; and a vent management member having a divider wall that separates an inner channel of the vent management member from an outer channel of the vent management member. The inner channel opens toward the cell stack. The inner channel is configured to communicate a flow of vent byproducts in a first direction to a position where the flow of vent byproducts can move around the divider wall from the inner channel to the outer channel. The outer channel is configured to communicated the flow of vent byproducts in an opposite, second direction to at least one outlet from the vent management member.

Abstract: A traction battery pack assembly includes an enclosure, and a battery array within an interior of the enclosure. The battery array includes a plurality of battery cells. A thermal barrier of the assembly has a sheet and one or more barrier vent opening plugs that are each disposed within an barrier vent opening of the sheet. The one or more barrier vent opening plugs are spaced from the sheet.

Abstract: A traction battery pack assembly includes an enclosure, and a battery array within an interior of the enclosure. The battery array includes a plurality of battery cells. The assembly further includes a hanging barrier within the interior of the enclosure. The hanging barrier including an attachment flange that extends transversely from a hanging portion.

Abstract: A battery pack may include an enclosure assembly providing an interior that houses at least one battery array. The battery pack may include a pressure relief valve configured to selectively communicate a flow of vent byproducts from the interior of the enclosure assembly to an exterior of the enclosure assembly via an opening. Further, the battery pack may include a vent duct including a wall. When vent byproducts are communicated through the opening, the wall lies in a plane oblique to a centerline of the opening.

Abstract: A traction battery pack assembly includes a cell stack within an interior of an enclosure. The cell stack including a plurality of battery cells and a divider assembly disposed along a cell stack axis. The divider assembly is arranged between a first battery cell and a second battery cell of the plurality of battery cells. The divider assembly includes a compressible pad that includes a housing disposed about a foam.

Abstract: Battery cell stack designs are provided for traction battery packs. An exemplary cell stack may include a thermal barrier assembly that is arranged to inhibit the transfer of thermal energy between adjacent subgroupings of battery cells of the cell stack. The thermal barrier assembly may include a bulb seal for sealing an interface between the thermal barrier assembly and a perimeter environment (e.g., a heat exchanger plate, an enclosure tray, etc.). The bulb seal may seal any leak paths between the thermal barrier assembly and the perimeter environment, thereby preventing vent gases from passing from one battery cell subgrouping to another during battery thermal events.

Abstract: Battery cell stack cross-member assemblies are provided for traction battery packs. An exemplary cross-member assembly may include a thermally insulating sheet for blocking the transfer of thermal energy to adjacent structures inside the traction battery pack. The thermally insulating sheet incorporates thermal control valves in the form of movable flaps for controlling the flow of battery cell vent byproducts during battery thermal events.

Abstract: A battery pack venting system includes a battery pack enclosure providing an interior, and a cell stack within the interior. The cell stack includes one or more battery cells disposed along a cell stack axis. One or more structural members are disposed within the interior alongside an axial end portion of the cell stack. Each structural member including at least one channel. A shield is within the interior. The shield has a recess configured to receive vent byproducts released from the one or more battery cells. The shield is configured to redirect the vent byproducts into the at least one channel.

Abstract: Thermal management valve assemblies are provided for use within traction battery packs. An exemplary thermal management valve assembly may be configured to block the transfer of thermal energy to adjacent structures inside the traction battery pack during normal operating conditions and may be further configured to control the flow of battery cell vent byproducts during battery thermal events. The thermal management valve assembly may include one or more attachment frames that can be mounted to a cell stack cross-member assembly, and one or more thermal barriers that can be connected to the attachment frame(s).

Abstract: Thermal barrier shields are provided for traction battery packs. The thermal barrier shield may be arranged to inhibit the transfer of thermal energy from a cell packet of a cell stack to an enclosure cover of the traction battery pack. The cell packet may be arranged between a first structural thermal barrier assembly and a second structural thermal barrier assembly of the cell stack. The thermal barrier shield may be supported at a position between the enclosure cover and the cell packet by the first structural thermal barrier assembly and the second structural thermal barrier assembly.

Abstract: A battery pack system includes a battery pack enclosure housing a battery array, and a barrier assembly within the enclosure. The barrier assembly includes a container and an expandable foam contained within the container. A battery pack barrier providing method, includes positioning a container within an interior of a battery pack enclosure adjacent to at least one component within the interior, introducing an expandable foam into the container, and delivering the expandable foam through the container to at least one interface between the container and the at least one component.

Abstract: Battery cell stack cross-member assemblies are provided for traction battery packs. An exemplary cross-member assembly may include a thermally insulating sheet for blocking the transfer of thermal energy to adjacent structures inside the traction battery pack. The thermally insulating sheet incorporates thermal control valves in the form of releasable flaps for controlling the flow of battery cell vent byproducts during battery thermal events. A venting tape may secure the thermally insulating sheet to the cross-member assembly and may function to provide an opening mechanism for controlling the release of the flaps.

Abstract: Battery cell stack designs are provided for traction battery packs. An exemplary cell stack may include a thermal barrier assembly that is arranged to inhibit the transfer of thermal energy between adjacent cell packets of battery cells of the cell stack. The thermal barrier assembly may include a first seal for sealing a first interface between a heat exchanger plate and the thermal barrier assembly. A second seal may be provided for sealing a second interface between the heat exchanger plate and a structural plate member of the cell stack. A third seal may be provided for sealing a third interface between the heat exchanger plate and cross-member assembly of the cell stack. The first, second, and third seals may cooperate to establish a seal system for sealing various gas paths across the heat exchanger plate, thereby preventing vent gases from passing from one battery cell packet to another during battery thermal events as part of a cell vent management strategy.

Abstract: A battery pack assembly includes a cell stack having a plurality of battery cells, a thermal barrier adjacent the cell stack, and deflector hoods included within the thermal barrier. Each deflector hood configured to move from a closed position to an open position in response to a flow of vent byproducts against the deflector hood.