Battery Module Lateral Fastening for Standardized Pack Assembly

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Solution Overview

Problem

Existing battery modules lack standardized size and capacity for versatile application across various vehicles, and require improved fastening mechanisms to enhance robustness and space utilization in battery packs.

Innovation Solution

A battery module with standardized size and capacity, featuring lateral fastening portions on front and rear covers with through-holes, metal bushes, and insert nuts, allowing modules to be firmly fastened together and integrated into a battery pack, enhancing structural integrity and space efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If battery modules are designed with standardized size and capacity for versatile application, then adaptability to various vehicle types is improved, but device complexity increases due to standardized fastening mechanisms

Engineering Contradiction:

Improveadaptability to various vehicle typesVSAvoidcomplexity of fastening mechanism

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The battery module is divided into standardized segments with uniform fastening portions at regular intervals, allowing the same module design to be adapted to different vehicle configurations by simply changing the number and arrangement of modules rather than redesigning the fastening mechanism for each application

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fastening mechanism is designed with universal components including through-holes, metal bushes, and insert nuts that can serve multiple functions: fastening adjacent modules together, securing modules to battery pack cases, and providing alignment features during assembly, thereby reducing the need for separate specialized fastening components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If lateral fastening portions with through-holes, metal bushes, and insert nuts are added to enhance fastening strength, then strength of fastening is improved, but device complexity increases

Engineering Contradiction:

Improvestrength of fasteningVSAvoidcomplexity of module structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Multiple fastening functions are merged into a single integrated structure: the lateral fastening portions incorporate through-holes for bolt passage, metal bushes for reinforcement and alignment, and insert nuts for secure attachment, all within one unified component that protrudes from the module sides, eliminating the need for separate fastening elements

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Metal bushes serve as intermediary components between the through-holes and insert nuts, providing a reinforced interface that distributes mechanical loads, facilitates precise alignment during assembly, and protects the module housing from direct stress while enabling strong fastening connections

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If battery modules are firmly fastened to adjacent modules and cases, then reliability under external impacts is improved, but space utilization is reduced due to fastening structures

Engineering Contradiction:

Improveresistance to external impactsVSAvoidspace utilization in battery pack

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The fastening portions are positioned laterally on the sides of the battery module rather than extending outward in multiple directions, utilizing the lateral dimension for fastening operations. This allows bolts to pass through adjacent modules in a horizontal direction, minimizing vertical space requirements and allowing tighter stacking of modules within the battery pack volume

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

4Ease of manufacture

If standardized battery module design is implemented for consistent application, then ease of manufacture is improved, but adaptability to different vehicle configurations is reduced

Engineering Contradiction:

Improveconsistency in manufacturingVSAvoidflexibility for different vehicle types

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The standardized module design incorporates dynamic configurability through the arrangement and positioning of lateral fastening portions, which can be selectively engaged or disengaged, and through the lattice structure with adjustable extension elements, allowing the same manufactured module to be dynamically adapted to different vehicle spatial requirements and mounting configurations

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS12570136B2Battery module and battery pack including the same

Publication Date: 2026.03.10 HYUNDAI MOTOR CO LTD

AI summary

A battery pack comprises a plurality of battery modules. Each battery module of the plurality of battery modules includes: a stacked structure including a plurality of stacked battery cells; and a front cover and a rear cover respectively disposed on a front side and a rear side of the stacked structure, configured to cover the stacked structure, and including a cover surface facing the stacked structure, a first fastening portion laterally protruding from a first side of the stacked structure in a stacking direction of the plurality of stacked battery cells, and a second fastening portion laterally protruding from a second side of the stacked structure in the stacking direction.