Abstract: An electrochemical system having a thermal barrier layer is provided. The thermal barrier layer includes a polymer network having an inorganic portion and an organic portion such as silicone or a polysiloxane polymer network. The polymer network may further include filler component dispersed therein such as oxidized polyacrylonitrile milled fiber, Aerogel, hollow glass microspheres, and mica.

Abstract: A battery pack assembly includes a structural member of a battery pack; a module of the battery pack; and an attachment system having a plurality of cleats. The cleats can interlock to secure the module to the structural member. Mechanical fasteners can also be used to secure the module to the structural member.

Abstract: A battery pack assembly includes a first battery array, a second battery array adjacent the first battery array, and a thermal barrier assembly that blocks transfer of thermal energy between the first battery array and the second battery array. The thermal barrier assembly having a sheet of material that is folded to provide a plurality of layers.

Abstract: Battery pack designs for use in electrified vehicles may include a polymer-based enclosure having features for sealing external joints, retaining components inside the battery pack, securing electrical and coolant lines to the polymer-based enclosure, etc. The proposed designs reduce the number of overall parts in assembly, such as fasteners and brackets, and simplify the overall battery pack manufacturing and assembly processes.

Abstract: Battery pack designs for use in electrified vehicles may include a polymer-based enclosure having features for sealing external joints, retaining components inside the battery pack, securing electrical and coolant lines to the polymer-based enclosure, etc. The proposed designs reduce the number of overall parts in assembly, such as fasteners and brackets, and simplify the overall battery pack manufacturing and assembly processes.

Abstract: Battery pack designs for use in electrified vehicles may include a polymer-based enclosure having features for sealing external joints, retaining components inside the battery pack, securing electrical and coolant lines to the polymer-based enclosure, etc. The proposed designs reduce the number of overall parts in assembly, such as fasteners and brackets, and simplify the overall battery pack manufacturing and assembly processes.

Abstract: A battery pack assembly includes a first battery array, a second battery array adjacent the first battery array, and a thermal barrier assembly that blocks transfer of thermal energy between the first battery array and the second battery array. The thermal barrier assembly having a sheet of material that is folded to provide a plurality of layers.

Abstract: This disclosure details exemplary barrier seal assemblies for sealing vehicle electrical housings. The vehicle electrical housings may include any electrical housing utilized within a vehicle, including but not limited to battery pack housings and electrical connector assemblies. An exemplary barrier seal assembly may include a primary seal, a barrier seal, and a carrier that extends between the primary seal and the barrier seal. The barrier seal assembly is configured to reduce the ingress of corrosion inducing substances into an interior of vehicle electrical housings.

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 assembly includes a thermal exchange device of a battery pack, and battery arrays disposed adjacent the thermal exchange device. A phase change material is secured to an area of the thermal exchange device. A method of managing thermal energy within a battery pack includes, among other things, positioning battery arrays against a thermal exchange device, and securing a phase change material to the thermal exchange device. The phase change material is configured to take on thermal energy from at least one of the battery arrays.

Abstract: Exemplary battery pack designs for use in electrified vehicles may include an enclosure assembly that houses one or more battery internal components (e.g., battery arrays, battery electronic components, or both). A tear-away service panel may be positioned within a wall of the enclosure assembly. The service panel may be removed from the enclosure assembly to access one of the battery internal components requiring service and may be subsequently replaced with a replacement service panel. The replacement service panel may be part of a battery pack resealing kit.

Abstract: An electrochemical system having a thermal barrier layer is provided. The thermal barrier layer includes a polymer network having an inorganic portion and an organic portion such as silicone or a polysiloxane polymer network. The polymer network may further include filler component dispersed therein such as oxidized polyacrylonitrile milled fiber, Aerogel, hollow glass microspheres, and mica.

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 assembly includes a thermal exchange device of a battery pack, and battery arrays disposed adjacent the thermal exchange device. A phase change material is secured to an area of the thermal exchange device. A method of managing thermal energy within a battery pack includes, among other things, positioning battery arrays against a thermal exchange device, and securing a phase change material to the thermal exchange device. The phase change material is configured to take on thermal energy from at least one of the battery arrays.

Abstract: Battery pack designs for use in electrified vehicles may include a polymer-based enclosure having features for sealing external joints, retaining components inside the battery pack, securing electrical and coolant lines to the polymer-based enclosure, etc. The proposed designs reduce the number of overall parts in assembly, such as fasteners and brackets, and simplify the overall battery pack manufacturing and assembly processes.

Abstract: Exemplary battery pack designs for use in electrified vehicles may include an enclosure assembly that houses one or more battery internal components (e.g., battery arrays, battery electronic components, or both). A tear-away service panel may be positioned within a wall of the enclosure assembly. The service panel may be removed from the enclosure assembly to access one of the battery internal components requiring service and may be subsequently replaced with a replacement service panel. The replacement service panel may be part of a battery pack resealing kit.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include an enclosure assembly that houses one or more battery internal components (e.g., battery arrays, battery electronic components, or both). A tear-away service panel may be positioned within a wall of the enclosure assembly. The service panel may be removed from the enclosure assembly to access one of the battery internal components requiring service and may be subsequently replaced with a replacement service panel. The replacement service panel may be part of a battery pack resealing kit.

Abstract: This disclosure details exemplary barrier seal assemblies for sealing vehicle electrical housings. The vehicle electrical housings may include any electrical housing utilized within a vehicle, including but not limited to battery pack housings and electrical connector assemblies. An exemplary barrier seal assembly may include a primary seal, a barrier seal, and a carrier that extends between the primary seal and the barrier seal. The barrier seal assembly is configured to reduce the ingress of corrosion inducing substances into an interior of vehicle electrical housings.

Abstract: This disclosure details exemplary battery pack designs for use in electrified vehicles. Exemplary battery packs may include an enclosure assembly that houses one or more battery internal components (e.g., battery arrays, battery electronic components, or both). A tear-away service panel may be positioned within a wall of the enclosure assembly. The service panel may be removed from the enclosure assembly to access one of the battery internal components requiring service and may be subsequently replaced with a replacement service panel. The replacement service panel may be part of a battery pack resealing kit.

Abstract: An extruded interlocking flexible gasket with a first side with at a least one first side spline and at least one first side groove on the gasket to be positioned between a first member and a second member. The gasket further having a second side with at a least one second side spline and at least second first side groove on said extruded gasket, wherein said first side interlocks with said second side when said first side is immediately adjacent to said second permitting the at a least one first side spline to be interlocked with at least the second side groove, and extending continuously therealong.