Abstract: Systems are provided that enable external regress and service of a port assembly of a battery pack assembly. In one example, a system includes a first port casing member that is coupleable with a second port casing member that is tiered via a pair of fasteners that extend from the second port casing member to the first port casing member to compress a seal spaced between the first port casing member and the second port casing member, a port outlet positioned on a surface of the first port casing member, and a port inlet positioned on a surface of the second port casing member.

Abstract: A traction battery pack assembly includes a cell stack having a plurality of battery cells and one or more thermal barriers disposed along a cell stack axis. A crossmember is alongside the cell stack. One or more fasteners that secure the one or more thermal barriers to the crossmember. The fasteners can be staples.

Abstract: A traction battery pack port assembly includes an inner spigot that is securable in an installed position relative to an enclosure. The inner spigot is connectable to a battery pack conduit at a position inside the enclosure when the inner spigot is in the installed position. A fastener has an aperture that receives a portion of the inner spigot and secures the inner spigot to the enclosure. An outer spigot is removably securable to the inner spigot.

Abstract: Bus bar assemblies are provided for electrically connecting battery cells within a battery array of a traction battery pack. An exemplary bus bar assembly may include a ladder frame and a bus bar plate that is mounted to the ladder frame. In some implementations, the bus bar plate is an arched bus bar plate. The bus bar plate may provide suitable welding surfaces for joining both battery cell tab terminals and sense leads to the bus bar plate. The battery cell tab terminals may be joined to the bus bar plate without positioning the bus bar plate perpendicular to the tab terminals and without bending the tab terminals.

Abstract: A thermal management system for a traction battery pack includes at least one cell stack having a plurality of battery cells, and a thermal exchange device adjacent the at least one cell stack. The thermal exchange device has at least one coolant passageway that communicates a coolant. A riser is coupled to the thermal exchange device. The riser is configured to fluidly couple the thermal exchange device to a coolant delivery system.

Abstract: A method of assembling components of a traction battery includes dispensing a thermal interface material onto a release sheet. While the thermal interface material remains on the release sheet, the method applies the thermal interface material to a component of a traction battery pack. The method then separates the release sheet from the thermal interface material while the thermal interface material remains on the component of the traction battery pack.

Abstract: A battery assembly includes an enclosure providing an interior. The enclosure has a wall and a service panel. The service panel is secured to the wall with at least one snap-lock seam to cover a service opening in the wall. A method includes securing a service panel to a wall of an enclosure using at least one snap-lock seam. The service panel covers a service opening in the wall when secured to the wall.

Abstract: A battery pack assembly, including: a header configured to transition from an uninstalled position relative to an enclosure to an installed position relative to the enclosure. The header in the installed position disposed over an opening in the enclosure. The header in the installed position receiving a portion of a busbar when the header is in the installed position.

Abstract: An traction battery pack assembly includes a first plate and a second plate secured adjacent to the first plate to provide at least one coolant passage that extends through an interior area of a battery pack enclosure. The at least one coolant passage is between the first plate and the second plate. A connector is fluidly coupled to the at least one coolant passage. The connector is removably connectable with a conduit at a position outside the battery pack enclosure.

Abstract: A battery pack electrical connector assembly includes an outer connector having a collar that bonds to an enclosure. The outer connector includes one or more outer connector apertures, and an inner connector configured to transition back-and-forth between an engaged position and a disengaged position with the outer connector. The inner connector is received within one of the outer connector apertures when in the engaged position.

Abstract: “Spacerless” cell block assemblies are provided for traction battery packs. Exemplary cell block assemblies may include a battery cell grouping, a bus bar module, and a heat exchanger plate. The battery cell grouping may be arranged between the bus bar module and the heat exchanger plate. The bus bar module may provide first spacer features, and the heat exchanger plate may provide second spacer features. The first and second spacer features cooperate to maintain air gaps between adjacent battery cells of the battery cell grouping.

Abstract: A traction battery assembly includes a busbar, a carrier frame having a pocket that receives the busbar, and a cap secured to the carrier frame to contain the busbar within the pocket. A busbar retention method includes positioning at least one busbar with a pocket of a carrier frame and resting the busbar on at least one ledge and securing a cap to the carrier frame to hold the at least one busbar within the pocket.

Abstract: A traction battery pack partitioning method includes providing a battery pack having an enclosure that houses at least a first battery array and a second battery array within an interior area, and, in response to thermal energy released from at least one battery cell in the first battery array, expanding a material to partition the interior area into a first subarea that houses the first battery area and a second subarea that houses the second battery array.

Abstract: An exemplary method of securing a battery array includes attaching a twist-lock to a case, and securing a battery array to the case by rotating the twist-lock from a first position to a second position. Another exemplary method of securing a battery array includes securing a twist-lock to a case, and rotating the twist-lock from a first position to a second position where a portion of a battery array is clamped between the twist-lock and the case.

Abstract: A battery pack includes a support structure, an array frame including a fastener housing, and a fastener received through the fastener housing for mounting the array frame to the support structure. The array frame may be mounted to the support structure using a top-down approach that includes inserting a fastener through a fastener housing of the array frame.

Abstract: An exemplary support assembly for a battery array includes a spacer axially separating a first battery cell from a second battery cell, a frame that holds the spacer, and an insert secured to the frame. The insert is compressed against the first battery cell. An exemplary method of supporting a battery cell includes compressing an insert against a corner region of a battery cell. The insert is secured to a frame made of a first material. The insert is made of a second material that is softer than the first material.

Abstract: An exemplary method includes, among other things, providing first and second blanks that are nominally identical and that include an array of raised features. The method further includes removing a first combination of individual raised features from the first blank to provide a first battery component with a first flow path, and removing a different, second combination of individual raised features from the second blank to provide a second battery component with a different, second flow path. An exemplary battery assembly includes, among other things, a blank having a plurality of ribs extending from a floor. The blank is configured such that a first combination of the ribs are removable from the blank to provide a first battery component having first flow path, and a different, second combination of the ribs are removable from the blank to provide a second battery component having a different, second flow path.

Abstract: A battery pack includes a heat dissipating structure, an array frame positioned against the heat dissipating structure, and a battery cell retained by the array frame and arranged so at least one surface of the battery cell is exposed by the array frame and is contiguous with the heat dissipating structure. The heat dissipating structure may be a heat exchanger plate or a thermal interface material (TIM).

Abstract: An exemplary method of securing portions of a battery pack includes, among other things, slidably engaging a portion of a battery cell frame within a channel of an extrusion, and securing the extrusion to a support to secure the battery cell frame.

Abstract: An exemplary support assembly for a battery array includes, among other things, a frame and an insert secured to the frame. The insert is configured to hold at least one battery cell within the frame. The frame is made of a first material and the insert is made of a second material that is softer than the first material. An exemplary method of securing a battery cell within a traction battery pack of an electrified vehicle includes, among other things, compressing an insert against the at least one battery cell. The insert is secured to a frame made of a first material. The insert is made of a second material that is softer than the first material.