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.

Abstract: A battery pack includes a grouping of battery cells and a plurality of array frames for retaining the grouping of battery cells. Each of the plurality of array frames includes a ratchet feature. A column bolt includes a raised surface configured to mate with the ratchet feature of each of the plurality of array frames to secure the plurality of array frames together.

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 battery assembly includes, among other things, a thermal fin, a frame holding the thermal fin, and a stand-off of the frame configured to limit relative movement of the thermal fin toward a thermal exchange plate. An exemplary thermal fin positioning method, includes limiting relative movement of a thermal fin toward a thermal exchange plate using a stand-off disposed upon a battery cell assembly frame.

Abstract: A battery pack includes a support structure, an array frame mounted relative to the support structure, and a thermal fin held within the array frame and grounded to the support structure. The thermal fin may include a grounding extension that is grounded to the support structure.

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: A battery cooling and retainer assembly according to an exemplary aspect of the present disclosure includes, among other things, a first retainer section that includes a first retention feature, a second retainer section that includes a second retention feature, and a cooling channel disposed between the first retainer section and the second retainer section.

Abstract: A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a terminal holder, a terminal at least partially surrounded by the terminal holder, and a bus bar module connectable to the terminal holder. One of the terminal holder and the bus bar module includes at least one locating feature to position the bus bar module in a welding position relative to the terminal.