Battery Container Structure Without Rack Frames for Higher Energy Density

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Solution Overview

Problem

Conventional battery containers face challenges due to the significant weight increase caused by rack frames, leading to difficulties in transportation, increased costs, and reduced energy density.

Innovation Solution

A battery container design featuring a container housing with unit housings forming empty spaces, accommodating battery modules stacked in an upper and lower direction, and supported by a support member that eliminates the need for a separate rack frame.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a rack frame is used to maintain the stacked state of battery modules, then the structural stability is improved, but the weight of the battery container increases significantly

Engineering Contradiction:

Improvestructural stabilityVSAvoidweight of battery container

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The patent merges the rack frame structure with the container housing by integrating support ribs directly into the housing walls. The housing itself is designed to provide structural support through its ribbed configuration, eliminating the need for a separate rack frame while maintaining the ability to stack and support battery modules securely.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The container housing is designed to serve multiple functions simultaneously: it provides enclosure for battery modules, structural support for stacking, and integration with support members. The housing's ribbed structure and integrated support features allow it to perform both containment and structural stabilization functions that were previously requiring separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If a rack frame is used to accommodate battery modules, then the structural support is improved, but the size of the battery container increases

Engineering Contradiction:

Improvestructural supportVSAvoidsize of battery container

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The support function previously requiring a separate rack frame is merged into the container housing structure itself. The housing includes integrated support ribs and features that provide the necessary structural support for accommodating and stacking battery modules, eliminating the need for additional space-consuming rack components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support structure is nested within the container housing walls rather than being a separate external component. The support ribs are formed as integral parts of the housing structure, allowing the support function to be embedded within the existing housing volume without increasing the overall container size.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Stability of the object's composition

If a rack frame is used to maintain battery modules, then the structural integrity is improved, but the space for battery modules is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidspace for battery modules

Core Design Contradiction:

Stability of the object's compositionVSVolume of stationary object

Solution Approach 1:

The structural integrity function is merged into the container housing itself through integrated support ribs and structural features. This eliminates the need for a separate rack frame that would occupy internal space, allowing maximum volume to be dedicated to battery module accommodation while maintaining structural integrity through the housing's own design.

Inventive Principle:

Principle #5Merging (Combining)

4Stability of the object's composition

If a rack frame is used to support battery modules, then the structural stability is improved, but the manufacturing cost increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

Stability of the object's compositionVSEase of manufacture

Solution Approach 1:

The patent combines the rack frame support function with the container housing into a single integrated structure. This reduces the total number of parts that need to be manufactured, assembled, and inventoried, thereby lowering manufacturing costs while maintaining the structural stability needed to support and stack battery modules securely.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The container housing is designed to perform multiple functions including enclosure, structural support, and module accommodation. By making the housing multi-functional, the patent eliminates the need for separate rack frame components, reducing manufacturing complexity and cost while maintaining structural stability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20250038339A1Battery container and energy storage system including the same

Publication Date: 2025.01.30 LG ENERGY SOLUTION LTD

AI summary

A battery container includes a container housing having a plurality of unit housings to form an empty space therein; a plurality of battery modules accommodated in the inner space of the container housing and stacked in an upper and lower direction to form a module stack, so that a plurality of module stacks are arranged in a horizontal direction; and a support member configured to accommodate the plurality of battery modules while supporting at least two unit housings therebetween.