Abstract: An electrified vehicle system includes a battery having a plurality of cells electrically connected in at least one cell array, the at least one cell array connected to an internal battery busbar within a housing, an annular coolant fitting having a coolant channel extending between an outer radius and an inner radius of the fitting, and an electrically conductive fastener having a closed end and a channel extending from an open end to a radial opening, the fastener extending through the annular coolant fitting with the radial opening positioned within the annular coolant fitting, and further extending through the housing and mechanically and electrically connecting an external busbar outside the housing to the internal busbar, and facilitating coolant flow through the battery array.

Abstract: This disclosure describes charging systems for electrified vehicles. Exemplary charging systems may employ a multi-voltage charging circuit that supports charging of a traction battery pack at both a first voltage level during a first charging condition and a second, different voltage level during a second charging condition. Higher voltage levels may be experienced during the second charging condition as compared to the first charging condition.

Abstract: Exemplary battery cell designs, such as those for use within electrified vehicle traction battery packs, for example, may include an electrode assembly that includes a plurality of current collector tabs. The current collector tabs may be arranged in one or more tab groupings when the electrode assembly is positioned in a folded configuration. The current collector tabs of the one or more tab groupings may be joined together to establish an enlarged current collector tab that is larger than any individual one of the current collector tabs of the one or more tab groupings. The enlarged current collector tab is an optimized tab configured to reduce internal resistance, reduce heat buildup, and increase the power capability of the battery cell.

Abstract: A vehicle includes a fuel cell stack, a traction battery, at least one DC/DC converter electrically coupling the fuel cell stack and the traction battery to a DC bus, an electric machine coupled to the DC bus via an inverter, and a controller programmed to control the at least one DC/DC converter to provide a DC bus voltage to maximize efficiency of the electric machine based on torque, rotational speed, and temperature of the electric machine.

Abstract: This disclosure details exemplary immersion cooling battery array designs for use in electrified vehicle battery packs or other electrified components. An exemplary battery array design may include a battery subassembly including a compressible spacer assembly and a plurality of battery cells held by the compressible spacer assembly. The battery subassembly may be surrounded by an outer shell assembly. A non-conductive (i.e., dielectric) fluid may be received and communicated inside the outer shell assembly for thermally managing heat generated by the battery cells.

Abstract: A vehicle includes an electric machine, a traction battery pack, and a battery controller. The traction battery pack includes a plurality of cell modules electrically connected with the electric machine. Each of the cell modules includes a housing having a battery cell, a passive circuit element isolated from the battery cell, and a module controller contained therein. The passive circuit elements are electrically connected in series or parallel. The battery controller is in communication with each of the module controllers and is electrically connected with the passive circuit elements. Responsive to signals from the module controllers indicative of a total number of the cell modules and a measured parameter associated with the passive circuit elements being indicative of a same total number of the cell modules, the battery controller operates the battery cells according to power limits defined by the total number.

Abstract: Exemplary battery cell designs, such as those for use within electrified vehicle traction battery packs, for example, may include an electrode assembly that includes a plurality of current collector tabs. The current collector tabs may be arranged in one or more tab groupings when the electrode assembly is positioned in a folded configuration. The current collector tabs of the one or more tab groupings may be joined together to establish an enlarged current collector tab that is larger than any individual one of the current collector tabs of the one or more tab groupings. The enlarged current collector tab is an optimized tab configured to reduce internal resistance, reduce heat buildup, and increase the power capability of the battery cell.

Abstract: A vehicle includes an electric machine, a traction battery pack, and a battery controller. The traction battery pack includes a plurality of cell modules electrically connected with the electric machine. Each of the cell modules includes a housing having a battery cell, a passive circuit element isolated from the battery cell, and a module controller contained therein. The passive circuit elements are electrically connected in series or parallel. The battery controller is in communication with each of the module controllers and is electrically connected with the passive circuit elements. Responsive to signals from the module controllers indicative of a total number of the cell modules and a measured parameter associated with the passive circuit elements being indicative of a same total number of the cell modules, the battery controller operates the battery cells according to power limits defined by the total number.

Abstract: This disclosure describes charging systems for electrified vehicles. Exemplary charging systems may employ a multi-voltage charging circuit that supports charging of a traction battery pack at both a first voltage level during a first charging condition and a second, different voltage level during a second charging condition. Higher voltage levels may be experienced during the second charging condition as compared to the first charging condition.

Abstract: This disclosure details exemplary immersion cooling battery array designs for use in electrified vehicle battery packs or other electrified components. An exemplary battery array design may include a battery subassembly including a compressible spacer assembly and a plurality of battery cells held by the compressible spacer assembly. The battery subassembly may be surrounded by an outer shell assembly. A non-conductive (i.e., dielectric) fluid may be received and communicated inside the outer shell assembly for thermally managing heat generated by the battery cells.

Abstract: A vehicle-to-building power system allows a vehicle to power a building. The system includes a power-receiving unit remote from a vehicle. The unit includes a cable configured to mate with a vehicle port and support high-voltage electrical loads between the vehicle and the power-receiving unit. The unit further includes a high-voltage inverter configured to convert a direct current (DC) power supplied from a vehicle battery to an alternating current (AC) power compatible with a building electrical system, and a high-voltage DC bus electrically connected to the inverter. The bus has one or more contactors that electrically connect the cable to the high-voltage inverter when closed and electrically disconnect the cable and the high-voltage inverter when open.

Abstract: A vehicle-to-building power system allows a vehicle to power a building. The system includes a power-receiving unit remote from a vehicle. The unit includes a cable configured to mate with a vehicle port and support high-voltage electrical loads between the vehicle and the power-receiving unit. The unit further includes a high-voltage inverter configured to convert a direct current (DC) power supplied from a vehicle battery to an alternating current (AC) power compatible with a building electrical system, and a high-voltage DC bus electrically connected to the inverter. The bus has one or more contactors that electrically connect the cable to the high-voltage inverter when closed and electrically disconnect the cable and the high-voltage inverter when open.

Abstract: This disclosure details electrified vehicles that are equipped with secondary battery packs for increasing the electric range of the vehicles. An exemplary electrified vehicle includes a cargo space, such as a truck bed, and a secondary battery pack positioned within the cargo space. The secondary battery pack is adapted to selectively supply power for propelling one or more vehicle drive wheels. In some embodiments, the secondary battery pack is shaped like, and therefore disguised as, a toolbox.

Abstract: This disclosure details electrified vehicles that are equipped with secondary battery packs for increasing the electric range of the vehicles. An exemplary electrified vehicle includes a cargo space, such as a truck bed, and a secondary battery pack positioned within the cargo space. The secondary battery pack is adapted to selectively supply power for propelling one or more vehicle drive wheels. In some embodiments, the secondary battery pack is shaped like, and therefore disguised as, a toolbox.

Abstract: An exemplary battery support assembly includes a bladder device with a pocket that receives at least one battery cell of a traction battery. The bladder provides a fluid flow path that diverges at an end of the pocket into a first section on a first side of the pocket and a second section on an opposing, second side of the pocket. An exemplary battery support method includes moving a flow of fluid along a fluid flow path toward at least one battery cell; and diverging the flow into a first or second section of the fluid flow path such that the flow moves along opposing sides of the at least one battery cell.

Abstract: A battery thermal management system includes an inner housing containing a plurality of battery cells, and an outer housing enclosing the inner housing. A fluid channel is defined between an exterior surface of the inner housing and an interior surface of outer housing. The thermal management system also includes a fluid circulator in fluid flow communication with the fluid channel to selectively circulate one of a first thermal fluid and a second thermal fluid through the fluid channel.

Abstract: An exemplary battery support assembly includes a bladder device with a pocket that receives at least one battery cell of a traction battery. The bladder provides a fluid flow path that diverges at an end of the pocket into a first section on a first side of the pocket and a second section on an opposing, second side of the pocket. An exemplary battery support method includes moving a flow of fluid along a fluid flow path toward at least one battery cell; and diverging the flow into a first or second section of the fluid flow path such that the flow moves along opposing sides of the at least one battery cell.

Abstract: A battery thermal management system includes an inner housing containing a plurality of battery cells, and an outer housing enclosing the inner housing. A fluid channel is defined between an exterior surface of the inner housing and an interior surface of outer housing. The thermal management system also includes a fluid circulator in fluid flow communication with the fluid channel to selectively circulate one of a first thermal fluid and a second thermal fluid through the fluid channel.

Abstract: A battery testing method according to an exemplary aspect of the present disclosure includes, among other things, controlling a temperature of an environmental chamber that houses at least one battery cell during a test cycle to maintain a relatively constant temperature of the at least one battery cell throughout the test cycle.

Abstract: A vehicle is disclosed that includes a battery and a controller programmed to calculate a battery voltage characteristic from previously measured charge and discharge data. The battery voltage characteristic is based on differences between the previously measured values when state of charge falls in a range in which the differences are approximately equal. Outside of the range, the charge and discharge voltage data are corrected based on a square root of time to obtain the battery voltage characteristic. The characterization may be performed with a high-rate continuous charge and discharge cycle. Also disclosed is an apparatus for generating the battery characteristic that includes a bi-directional power supply. The battery voltage characteristic is obtained based on the differences of the charge and discharge voltage data and corrected data based on the square root of time. A method is also disclosed based on the same.