Battery Pack Guide Rail Assembly for Compact, Damage-Free Insertion

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Solution Overview

Problem

The assembly process of battery packs is inefficient and prone to damage due to collisions between the battery module and the outer housing, leading to increased manufacturing costs and reduced durability.

Innovation Solution

A battery pack design featuring guide rails and protrusions that guide the module case's vertical insertion, compression protrusions to eliminate gaps, and a stopper to limit vertical movement, along with a bumper portion to absorb external impacts, ensuring stable coupling and preventing component damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the battery module is inserted into the narrow internal space of the outer housing, then the battery pack structure is compact, but collision between the battery module and outer housing occurs causing damage

Engineering Contradiction:

Improveinternal space utilizationVSAvoidbattery module durability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

Guide rails are introduced as intermediary components between the battery module and outer housing. These guide rails provide a controlled insertion path that prevents direct collision between the battery module and the narrow internal space boundaries, enabling compact packaging while protecting the battery module from damage during assembly.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The guide rails are pre-installed on the inner surface of the outer housing before battery module insertion. This preliminary action creates a prepared guidance system that directs the battery module along a safe path, preventing collisions before they can occur during the insertion process.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the coupling structure has gaps after assembly, then the battery module can be easily inserted, but frequent friction or collisions occur during vehicle use causing component damage

Engineering Contradiction:

Improveassembly easeVSAvoidcomponent durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Compression protrusions are strategically placed at specific locations on the guide protrusion portions to apply localized pressure. This local quality approach eliminates gaps at critical coupling points while maintaining the overall ease of insertion, preventing friction and collisions during vehicle operation without complicating the assembly process.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coupling parameters are changed by introducing compression protrusions that modify the contact pressure and gap dimensions between the battery module and outer housing. This parameter adjustment eliminates harmful gaps that cause friction and collisions, improving reliability while maintaining assembly simplicity.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If the assembly process is difficult and time-consuming, then secure coupling is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvecoupling securityVSAvoidassembly efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The guide rails and guide protrusion portions create a self-aligning assembly system. The guide protrusion portions automatically follow the guide rails during insertion, and the compression protrusions automatically eliminate gaps through controlled pressure. This self-service mechanism achieves secure coupling without requiring complex assembly procedures or additional fastening operations, maintaining high productivity.

Inventive Principle:

Principle #25Self-service

4Ease of manufacture

If the guide protrusion portion moves along the guide rail without compression, then assembly is simple, but gaps remain causing collisions during vibration

Engineering Contradiction:

Improveassembly simplicityVSAvoidexternal impact damage

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

Compression protrusions are designed to apply beforehand cushioning pressure at the coupling interface between the guide protrusion portion and guide rail. This pre-compression eliminates gaps before external vibrations or impacts occur during vehicle use, preventing collisions and damage without complicating the assembly process.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12525677B2Battery pack, electronic device, and vehicle

Publication Date: 2026.01.13 LG ENERGY SOLUTION LTD

AI summary

A battery pack includes a battery module including a plurality of secondary batteries and a module case having a first internal space in which the secondary batteries are received; and a pack housing having an intermediate housing forming a second internal space in which the module case is received. At least one guide rail is disposed on an inner surface of the intermediate housing, the guide rail protruding in an inward direction toward the battery module and extending in a vertical direction to guide the insertion of the module case in the vertical direction. At least one guide protrusion portion on an outer surface of a horizontal direction of the module case, the guide protrusion portion protruding in an outward direction and extending in the vertical direction to move in the vertical direction along the guide rail, and having at least one compression protrusion to press the guide rail.