Battery Pack Lower End Plate Integration for Energy Density
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Solution Overview
Problem
Current battery pack structures face issues with energy density, assemblability, durability, and manufacturing costs due to the need for additional fastening members and complex structures, which can lead to instability and increased production time.
Innovation Solution
A battery pack design featuring a cell assembly with vertically stacked secondary cells and cartridges, where a metallic lower end plate is embedded within a plastic pack case, and the lower cover is laser-welded to the housing, eliminating the need for external fastening members and enhancing rigidity and sealability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastening members such as bolts and nuts are used to fix the cell assembly to the pack case, then the cell assembly can be secured, but additional spaces are required for fastening members and processes, decreasing energy density and complicating the structure
Solution Approach 1:
The end plate is integrated directly into the pack case structure, merging two separate components (end plate and pack case) into a unified structure. This eliminates the need for separate fastening members and reduces structural complexity while maintaining fixation stability.
Solution Approach 2:
The fastening members (bolts and nuts) are extracted/removed from the system. The invention achieves fixation without these additional components by using the integrated end plate structure that inherently secures the cell assembly.
2Reliability
If fastening members are used to fix the cell assembly, then the cell assembly can be secured, but the fastening members may become loose due to vibrations or impacts, causing breakage or damage
Solution Approach 1:
By merging the end plate with the pack case into a single integrated structure, the invention eliminates the fastening interface that would be susceptible to loosening from vibrations and impacts. The unified structure inherently maintains fixation stability under dynamic conditions.
3Reliability
If additional fastening members and processes are used, then the cell assembly can be fixed, but productivity decreases and manufacturing costs increase
Solution Approach 1:
The integration of the end plate into the pack case reduces the number of assembly steps and components. This merging of structures simplifies the manufacturing process, improves productivity, and reduces assembly complexity while maintaining reliable fixation.
4Reliability
If spaces are allocated for fastening members and processes in the pack case, then the cell assembly can be fixed, but the energy density of the battery pack decreases
Solution Approach 1:
The invention extracts/eliminates the need for additional spaces for fastening members by using an integrated end plate structure. This removes unnecessary volume from the pack case, allowing more space for active materials and improving energy density while maintaining fixation stability.
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
This design improves assemblability and productivity, increases energy density by removing unnecessary space, and ensures stable fixation and durability, preventing breakage and foreign substance permeation, while reducing manufacturing costs and complexity.
Implementation Method 1
the lower cover being fixedly coupled to the lower housing
Data Source
AI summary
The present disclosure relates to a battery pack having improved assemblability, processability, and productivity, and configured to reduce manufacturing costs and enhance the scalability and durability of a pack case. The battery pack includes: a cell assembly including a plurality of secondary cells and a plurality of cartridges, the cartridges being configured to be stacked on one another and to accommodate the secondary cells while surrounding outer circumferential portions of the secondary cells from outsides of the secondary cells; a lower housing having an empty inner space to accommodate the cell assembly in the inner space, the lower housing being opened on an upper side thereof; a lower end plate including a plate-shaped metallic material and placed in surface contact with a lower surface of the lower housing; and a lower cover placed on a lower portion of the lower end plate to cover the lower end plate, the lower cover being fixedly coupled to the lower housing.