Integrated Battery Module Housing for Faster Assembly

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Solution Overview

Problem

The assembly productivity and cost of battery modules are hindered by the use of welding and fasteners in constructing module housings, which complicate the integration of multiple battery cells.

Innovation Solution

A battery module design featuring a module housing made of synthetic resin with integrated busbar holders and sidewalls, reinforced by a metal reinforcing member, and incorporating features like insert molding and a cooling plate for improved assembly and thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding or fasteners are used to couple end plates and side plates in module housing, then structural strength is improved, but assembly productivity decreases and manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidassembly productivity

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The module housing is designed as an integrated structure where end plates and side plates are coupled together using welding or fasteners to form a unified housing assembly, eliminating the need for separate coupling components and improving assembly productivity

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If welding or fasteners are used to couple end plates and side plates in module housing, then structural strength is improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If multiple separate components are used in module housing, then ease of assembly is improved, but device complexity increases

Engineering Contradiction:

Improveease of assemblyVSAvoiddevice complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The module housing integrates end plates and side plates into a unified structure with busbar holders and sidewalls, reducing the total number of separate components and simplifying the overall device complexity while maintaining ease of assembly through the integrated design

Inventive Principle:

Principle #5Merging (Combining)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances assembly efficiency, reduces costs, and improves thermal management and safety through integrated construction and enhanced heat dissipation.

Implementation Method 1

The reinforcing member may be inserted in a mold for molding the module housing and joined to the sidewall portion by insert molding

Methodology Applied

Scientific EffectInsert molding:

Implementation Method 2

the battery module may further include a cooling plate that cools the battery cell stack and is fastened to the fastener and coupled to the module housing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20260005357A1Battery module

Publication Date: 2026.01.01 SAMSUNG SDI CO LTD

AI summary

A battery module includes a battery cell stack including a plurality of battery cells, a plurality of busbars electrically connecting the plurality of battery cells, and a module housing made of a synthetic resin material, and including a busbar holder portion supporting the plurality of busbars, and a sidewall portion surrounding side surfaces of the battery cell stack that does not face the busbar holder portion and connected to the busbar holder portion.