Battery Pack Case Reinforcement for Space-Efficient Cell Layout

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Solution Overview

Problem

Conventional battery packs face challenges in maximizing space utilization and battery capacity, particularly in medium and large-sized applications, and require improved rigidity and ease of assembly without welding.

Innovation Solution

A battery pack design featuring a pack case with separable portions, reinforcing members, and connection members using bolts to connect and reinforce the case, allowing for efficient stacking and arrangement of battery cells.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the pack case is made as a single integrated structure, then structural strength is maintained, but space utilization is reduced

Engineering Contradiction:

Improvespace utilizationVSAvoidstructural strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The pack case is divided into multiple separate frames (first side frame, second side frame, first barrier frame, second barrier frame) that are positioned at different locations within the battery pack. These segmented frames work together to provide structural support while allowing optimized space utilization for battery cells in the regions between them.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If the pack case is separated to improve space utilization, then space utilization increases, but rigidity deteriorates

Engineering Contradiction:

Improvespace utilizationVSAvoidrigidity

Core Design Contradiction:

Volume of moving objectVSStability of the object's composition

Solution Approach 1:

Reinforcing members are introduced as intermediary elements that connect the separated frames (side frames and barrier frames). These reinforcing members act as mediators that restore structural rigidity and stability to the pack case while allowing the frames themselves to be separated for optimized space utilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If welding is used to connect pack case components, then connection strength is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The connection between pack case components is achieved through mechanical fastening using bolts and fastening grooves instead of welding. This substitution replaces a thermal joining process with a mechanical joining process, maintaining connection strength while significantly improving ease of manufacture and assembly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP4708508A1Battery pack and vehicle including same

Publication Date: 2026.03.11 LG ENERGY SOLUTION LTD

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AI summary

Disclosed is a battery pack and a vehicle including the same. The battery pack includes a plurality of battery cells; a pack case configured to accommodate the plurality of battery cells, so that at least a portion of the pack case is separated; a reinforcing member inserted into the separated portion of the pack case; and a connection member configured to connect the pack case and the reinforcing member.