Abstract: A traction battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a tray, at least one battery module, a lid secured to the tray to provide an enclosure having an interior that houses the at least one battery module, the lid having a lid aperture, and a reinforcement member is secured directly to the lid. The reinforcement member has a reinforcement member aperture. A fastener extends through the lid aperture and the reinforcement member aperture. The fastener is secured to a structure within the interior. The reinforcement member is secured directly to the lid separately from the fastener.

Abstract: A traction battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a tray, at least one battery module, a lid secured to the tray to provide an enclosure having an interior that houses the at least one battery module, the lid having a lid aperture, and a reinforcement member is secured directly to the lid. The reinforcement member has a reinforcement member aperture. A fastener extends through the lid aperture and the reinforcement member aperture. The fastener is secured to a structure within the interior. The reinforcement member is secured directly to the lid separately from the fastener.

Abstract: A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.

Abstract: This disclosure relates to a battery assembly for an electrified vehicle and a corresponding method. An exemplary battery assembly includes a battery cell including a terminal, a busbar, and at least one first weld bead securing the busbar to the terminal. The at least one first weld bead is substantially Z-shaped.

Abstract: An exemplary attachment method includes, among other things, to electrically couple a first battery cell to a busbar, joining a terminal of the first battery cell to the busbar with a first weld. The method further includes, to electrically couple a second battery cell to the busbar, joining a terminal of the second battery cell to the terminal of the first battery cell with a second weld. An exemplary attachment assembly includes, among other things, a busbar, a first terminal of a first battery cell, and a second terminal of a second battery cell. The first terminal is electrically coupled to the busbar with a first weld that joins the first terminal to the busbar. The second terminal is electrically coupled to the busbar with a second weld that joins the second terminal to the first terminal.

Abstract: A busbar assembly includes, among other things, a busbar, a battery terminal, and a deformed area securing together the busbar and the battery terminal. A securing method includes, among other things, positioning a first portion of an attachment structure within an aperture, deforming a second portion of the attachment structure to provide a deformed area, and using the deformed area to secure a busbar relative to a battery terminal.

Abstract: A busbar assembly includes, among other things, a busbar, a battery terminal, and a deformed area securing together the busbar and the battery terminal. A securing method includes, among other things, positioning a first portion of an attachment structure within an aperture, deforming a second portion of the attachment structure to provide a deformed area, and using the deformed area to secure a busbar relative to a battery terminal.

Abstract: An exemplary attachment method includes, among other things, to electrically couple a first battery cell to a busbar, joining a terminal of the first battery cell to the busbar with a first weld. The method further includes, to electrically couple a second battery cell to the busbar, joining a terminal of the second battery cell to the terminal of the first battery cell with a second weld. An exemplary attachment assembly includes, among other things, a busbar, a first terminal of a first battery cell, and a second terminal of a second battery cell. The first terminal is electrically coupled to the busbar with a first weld that joins the first terminal to the busbar. The second terminal is electrically coupled to the busbar with a second weld that joins the second terminal to the first terminal.

Abstract: This disclosure relates to a battery assembly for an electrified vehicle and a corresponding method. An exemplary battery assembly includes a battery cell including a terminal, a busbar, and at least one first weld bead securing the busbar to the terminal. The at least one first weld bead is substantially Z-shaped.

Abstract: A battery assembly includes a first battery cell including a first terminal, a bus bar connected to the first terminal, and a first weld bead for securing the bus bar to the first terminal. The first weld bead includes a first end portion extending continuously to a second end portion and configured such that the first end portion faces in a direction toward the second end portion.

Abstract: A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.

Abstract: A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.

Abstract: A battery assembly includes a first battery cell including a first terminal, a bus bar connected to the first terminal, and a first weld bead for securing the bus bar to the first terminal. The first weld bead includes a first end portion extending continuously to a second end portion and configured such that the first end portion faces in a direction toward the second end portion.

Abstract: An assembly connecting a battery bus bar to battery cell terminals, with the bus bar provided with spring clips. The clips fit over the battery terminals and hold the bus bar and terminals in contact, with welding attaching the clip to the terminals.

Abstract: An assembly and method of connecting a bus bar to battery cell terminals to produce a bus bar clip assembly. A bus bar is provided with spring clips. The clips fit over the battery terminals and hold the bus bar and terminals in contact for welding the components together.

Abstract: A method of welding a bus bar to battery cell terminals to produce a bus bar clip assembly. A bus bar is provided with spring clips. The clips fit over the battery terminals and hold the bus bar and terminals in contact for welding the components together.

Abstract: A bus bar assembly according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells and a bus bar assembly that electrically connects the plurality of battery cells. The bus bar assembly includes a flexible cable, a voltage sense lead connected to the flexible cable, and a bus bar connected to the voltage sense lead.

Abstract: A laser welding system and method of joining a plurality of parts includes a shielding enclosure assembly. The shielding enclosure assembly includes a tubular enclosure and is provided with a gas supply port and a gas evacuation port. An isolator is provided between a bottom end of the tubular enclosure and parts to be joined to contain shielding gas and may also provide electrical insulation insulating the shielding enclosure assembly from the parts to be joined.

Abstract: A vehicle traction battery assembly including a pair of battery cells and a busbar is provided. Each of the battery cells may include a terminal and one or more locating features. The busbar may span between the cells and define a pair of arms each having a member sized to at least partially interlock with the one or more locating features. The busbar may span between the cells such that the busbar covers at least a portion of upper surfaces defined by each of the cells. At least one of the terminal apertures may be spaced in between outer edges of the respective arms such that a first and second surface area provide space sufficient for weld spots.

Abstract: A bus bar assembly according to an exemplary aspect of the present disclosure includes, among other things, a plurality of battery cells and a bus bar assembly that electrically connects the plurality of battery cells. The bus bar assembly includes a flexible cable, a voltage sense lead connected to the flexible cable, and a bus bar connected to the voltage sense lead.