Abstract: An integrated endplate for a battery pack includes an inner wall and an outer wall. The outer wall has a first side adjacent to the inner wall and a second side opposite the first side. The outer wall includes a connector interface protruding from the second side and defining at least one aperture therethrough. The integrated endplate further includes at least one electrical connector extending between the inner wall and the outer wall to the at least one aperture of the connector interface.

Abstract: A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, a housing, an array of battery cells provided within the housing, and a thermal exchange assembly adjacent the array and including an inlet, an outlet, and a tube configured to direct fluid from the inlet to the outlet. Further, the tube is overmolded with the housing. This disclosure also relates to a method of forming a battery assembly.

Abstract: An exemplary battery pack heat exchanger includes a wall of an enclosure, and a heat exchanger lid held against the wall to provide a chamber that receives a fluid to exchange thermal energy with a battery array that is outside of the chamber. An exemplary method of managing battery pack thermal energy includes moving a fluid through a chamber within an enclosure wall of a battery pack to adjust thermal energy levels of the battery pack.

Abstract: A battery assembly according to a non-limiting aspect of the present disclosure includes, among other things, a housing, an array of battery cells provided within the housing, and a thermal exchange assembly adjacent the array and including an inlet, an outlet, and a tube configured to direct fluid from the inlet to the outlet. Further, the tube is overmolded with the housing. This disclosure also relates to a method of forming a battery assembly.

Abstract: An integrated endplate for a battery pack includes an inner wall and an outer wall. The outer wall has a first side adjacent to the inner wall and a second side opposite the first side. The outer wall includes a connector interface protruding from the second side and defining at least one aperture therethrough.

Abstract: An exemplary battery pack enclosure assembly includes a tensioning section that limits movement of a first enclosure side relative to a second enclosure side to resist expansion of at least one battery cell within a group of battery cells that are disposed along an axis between the first enclosure side and the second enclosure side.

Abstract: A two-part fastener for an assembly having a sealed joint formed by at least two flanges or sealing surfaces. A first flange defines a first opening, a second flange defines a second opening with a seal being disposed between the first and second flanges. The flanges and seal are secured together with a bolt and a receiver that defines a threaded hole for receiving the bolt. The receiver includes an end face engaging the first flange and a shoulder engaging the second flange. The spacing between the end face and the shoulder defines a gap for the seal. The shoulder of the receiver may include a weld bead that is welded to the second flange. In one embodiment, three flanges are assembled together with a seal between each flange.

Abstract: An exemplary battery pack enclosure assembly includes a tensioning section that limits movement of a first enclosure side relative to a second enclosure side to resist expansion of at least one battery cell within a group of battery cells that are disposed along an axis between the first enclosure side and the second enclosure side.

Abstract: An exemplary battery pack heat exchanger includes a wall of an enclosure, and a heat exchanger lid held against the wall to provide a chamber that receives a fluid to exchange thermal energy with a battery array that is outside of the chamber. An exemplary method of managing battery pack thermal energy includes moving a fluid through a chamber within an enclosure wall of a battery pack to adjust thermal energy levels of the battery pack.

Abstract: A two-part fastener for an assembly having a sealed joint formed by at least two flanges or sealing surfaces. A first flange defines a first opening, a second flange defines a second opening with a seal being disposed between the first and second flanges. The flanges and seal are secured together with a bolt and a receiver that defines a threaded hole for receiving the bolt. The receiver includes an end face engaging the first flange and a shoulder engaging the second flange. The spacing between the end face and the shoulder defines a gap for the seal. The shoulder of the receiver may include a weld bead that is welded to the second flange. In one embodiment, three flanges are assembled together with a seal between each flange.

Abstract: A traction battery assembly includes a base plate and a plurality of prismatic cells stacked in an array on the base plate. A spacer assembly surrounds and is in contact with at least a portion of each of the cells. Each of the spacers assemblies include a pair of brackets having retaining tabs configured to extend over and retain a top portion of the cell opposite the base plate and anchoring tabs extending away from a base of the array. A clamp is disposed along the array and is configured to anchor the anchoring tabs to the base.

Abstract: A vehicle traction battery assembly is provided which may include a support structure, a thermal interface component, and a pressure plate. The support structure may include a center bar arrangement and may be configured to support a thermal plate and battery cell array. The thermal interface component may be disposed between the array and plate. The pressure plate may be on an upper face of the array. The assembly may be configured to exert a force against the pressure plate to compress the thermal interface component between the thermal plate and array. The center bar arrangement may include a center bar extending along the array and may be shaped to define a passageway between the upper face and the center bar. The pressure plate may be at least partially disposed within the passageway.

Abstract: A traction battery assembly includes cells stacked in an array and a thermal plate positioned against the array. An interior of the thermal plate defines a C-channel formed from several chambers spanning a length of the array and configured to circulate fluid therein to facilitate heat transfer with the cells.

Abstract: A vehicle traction battery assembly includes at least one battery cell array, and an electronics assembly configured to manage power flow of the battery assembly. The vehicle traction battery assembly also includes a thermal plate defining a first portion in contact with the at least one array and a second portion in contact with the electronics assembly. During power flow, both of the at least one array and the electronics assembly exchange heat with the thermal plate.

Abstract: A vehicle traction battery assembly is provided which may include a support structure, a thermal interface component, and a pressure plate. The support structure may include a center bar arrangement and may be configured to support a thermal plate and battery cell array. The thermal interface component may be disposed between the array and plate. The pressure plate may be on an upper face of the array. The assembly may be configured to exert a force against the pressure plate to compress the thermal interface component between the thermal plate and array. The center bar arrangement may include a center bar extending along the array and may be shaped to define a passageway between the upper face and the center bar. The pressure plate may be at least partially disposed within the passageway.

Abstract: A vehicle traction battery heat sink includes a first fin having a cell contact portion in thermal contact with a plurality of battery cells. The first fin also includes a connector portion extending from the cell contact portion. The heat sink further includes a thermal plate in thermal contact with the connector portion and a thermal agent circulated within the thermal plate. The heat sink allows heat generated by the plurality of battery cells to be transferred through the fin to the thermal plate.

Abstract: A traction battery assembly includes cells stacked in an array and a thermal plate positioned against the array. An interior of the thermal plate defines a C-channel formed from several chambers spanning a length of the array and configured to circulate fluid therein to facilitate heat transfer with the cells.

Abstract: A traction battery assembly includes a base plate and a plurality of prismatic cells stacked in an array on the base plate. A spacer assembly surrounds and is in contact with at least a portion of each of the cells. Each of the spacers assemblies include a pair of brackets having retaining tabs configured to extend over and retain a top portion of the cell opposite the base plate and anchoring tabs extending away from a base of the array. A clamp is disposed along the array and is configured to anchor the anchoring tabs to the base.

Abstract: A battery assembly may include an array of battery cells each having upper and lower ends, a face extending therebetween and partially defining an exterior of the array, and terminals extending from the upper end. The battery assembly may also include an exo-support structure including a plurality of retainer segments configured to support the upper and lower ends and a thermal plate defining one or more channels extending along the exterior of the array. The thermal plate may be arranged to thermally communicate with the battery cells via the faces. The exo-support structure may further include another thermal plate defining one or more channels extending along another exterior of the array which are arranged to thermally communicate with the cells. The battery assembly may include at least one cell separator made of a thermally conductive material which is located between two adjacent cells.