Integrated Battery Pack Assembly With Bracket-Secured Cell Stacks

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Solution Overview

Problem

Conventional battery packs have redundant components that perform the same function, leading to reduced productivity and weight inefficiencies.

Innovation Solution

A simplified battery pack configuration that omits redundant components by using fixing brackets and support members to secure cell stacks within a pack housing, along with a cooling plate and bus bar assembly, enhancing electrical and thermal connectivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If conventional battery packs use separate housings for battery modules and pack, then structural integrity is maintained, but device complexity and weight increase due to redundant components

Engineering Contradiction:

Improvenumber of componentsVSAvoidstructural integrity

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The patent merges the battery module housing and pack housing into a single integrated housing structure. The housing simultaneously serves as both the module housing and pack housing, eliminating redundant components while maintaining structural integrity through a unified design that accommodates both functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing is designed to perform multiple functions: it serves as both the module housing and pack housing, providing both module-level and pack-level structural support. This multi-functional design reduces the total number of components while maintaining all necessary structural functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If conventional battery packs include redundant components for structural support, then reliability is improved, but productivity and weight reduction are compromised

Engineering Contradiction:

Improveassembly efficiencyVSAvoidstructural reliability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

By combining the module housing and pack housing into a single integrated structure, the patent reduces the number of assembly steps and components, thereby improving productivity while maintaining structural reliability through the unified housing design.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If fixing brackets contact battery cells directly, then structural support is enhanced, but risk of cell damage increases

Engineering Contradiction:

Improvefixing strengthVSAvoidcell damage risk

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The support member acts as an intermediary between the fixing bracket and the battery cells. The fixing bracket contacts the support member instead of directly contacting the battery cells, thereby providing structural support while preventing potential cell damage through the mediating support member.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12418067B2Battery pack and method of assembling the same

Publication Date: 2025.09.16 SK ON CO LTD

AI summary

A battery pack, may include: a plurality of cell stacks including a plurality of battery cells; a pack housing accommodating the plurality of cell stacks; a fixing bracket disposed between the plurality of cell stacks and the pack housing and between the plurality of cell stacks; and a fastening member fastening the fixing bracket to the pack housing, wherein the fixing bracket may be disposed to contact the plurality of battery cells on an upper side of the plurality of cell stacks.