Battery Pack HV Connection Sealing for Dense Module Layouts

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional battery packs face issues with reduced energy density, increased weight, and inadequate cooling and sealing performance, leading to potential overheating, ignition, and explosion risks due to inefficient heat dissipation and unsuitable HV cable connections.

Innovation Solution

A battery pack design featuring a module frame with opening parts for HV connection assemblies, including terminal busbars and sealing members, and a BDU module for electrical control, along with an insulating cooling liquid system to enhance cooling efficiency and sealing performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If multiple battery modules are concentratedly arranged to increase output, then power increases, but heat dissipation becomes difficult and temperature rises excessively

Engineering Contradiction:

ImproveoutputVSAvoidtemperature

Core Design Contradiction:

PowerVSTemperature

Solution Approach 1:

A heat dissipation member is introduced as an intermediary between adjacent battery modules to facilitate heat transfer. The heat dissipation member includes a heat dissipation tank that receives heat from battery cells and a heat dissipation fin that transfers heat to the surrounding environment, enabling effective thermal management in high-power battery packs.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The battery pack is divided into multiple battery modules, each equipped with its own heat dissipation member. This segmentation allows independent thermal management for each module, preventing heat accumulation and enabling better overall heat dissipation while maintaining high power output.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If internal beams are added to partition battery modules, then structural stability improves, but energy density decreases due to increased weight

Engineering Contradiction:

Improvestructural stabilityVSAvoidenergy density

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The heat dissipation member serves multiple functions: it provides structural support between battery modules (replacing traditional internal beams), facilitates heat dissipation, and maintains structural stability. This multi-functionality reduces the need for additional structural components, thereby improving energy density while maintaining stability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If conventional HV cable connections are used without sealing, then ease of manufacture improves, but sealing performance deteriorates leading to potential contamination

Engineering Contradiction:

Improveease of manufactureVSAvoidsealing performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The sealing member is integrated with the HV connection assembly, combining the electrical connection function and sealing function into a single component. This integration maintains ease of manufacture by using a unified structure while ensuring reliable sealing performance to prevent contamination of battery cells.

Inventive Principle:

Principle #5Merging (Combining)

4Volume of moving object

If battery modules are mounted without opening parts for HV connections, then space efficiency improves, but adaptability decreases for electrical connections

Engineering Contradiction:

Improvespace efficiencyVSAvoidadaptability for electrical connections

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

Opening parts are strategically provided at specific locations on the battery module housing where HV connections are needed, rather than creating large openings or compromising overall module integrity. This localized approach maintains space efficiency while providing necessary adaptability for electrical connections.

Inventive Principle:

Principle #3Local quality

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

Improves cooling efficiency, sealing performance, and space efficiency, reducing the risk of overheating and explosion while increasing energy density and stability against external shocks.

Implementation Method 1

a battery module including a battery cell stack | a module frame that houses the battery cell stack

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

sealing is applied between the HV connection assembly and the opening part

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Data Source

PatentUS20250343317A1Battery Pack and Device Including the Same

Publication Date: 2025.11.06 LG ENERGY SOLUTION LTD

AI summary

A battery pack includes: battery modules that include a battery cell stack containing a plurality of battery cells, and a module frame that houses the battery cell stack and has an opening part formed on one side; and a plurality of HV connection assemblies that electrically connect battery modules adjacent thereto, wherein the battery module includes a terminal busbar connected to at least one of the electrode leads of the battery cells, wherein the HV connection assemblies and the terminal busbars included in the adjacent battery modules are respectively connected through the opening part, and wherein sealing is applied between the HV connection assembly and the opening part.