Cross Beam Battery Pack Layout for Simpler Cell Fixation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional battery packs face challenges with increased manufacturing costs, complex assembly processes, reduced price competitiveness, and lower energy density due to the complex cell frame structure.

Innovation Solution

A battery pack design featuring a base plate, cross beam unit, and cover plate, where the cross beam unit is positioned between the battery cells to attach and fix them, enhancing strength and energy density while simplifying the structure to reduce costs and complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional cell frame structure including an assembly of multiple plates is used, then the battery pack can accommodate battery cells, but the manufacturing cost increases and assembly process complexity increases

Engineering Contradiction:

Improvebattery cell accommodationVSAvoidcell frame structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent removes the complex multi-plate cell frame structure from the battery pack design, retaining only the essential base plate for supporting battery cells. This extraction of unnecessary structural elements directly reduces device complexity and manufacturing cost while maintaining the core function of accommodating battery cells.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs a simplified base plate structure instead of expensive, complex multi-plate cell frames. This approach uses simpler, more cost-effective components that are easier to manufacture and assemble, directly addressing the manufacturing cost and assembly complexity issues.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Strength

If a conventional cell frame structure including an assembly of multiple plates is used, then the battery pack can provide structural support, but the total size increases and energy density decreases

Engineering Contradiction:

Improvestructural supportVSAvoidenergy density

Core Design Contradiction:

StrengthVSQuantity of substance

Solution Approach 1:

By removing the redundant multi-plate cell frame structure and retaining only the essential base plate, the patent reduces the total volume occupied by structural components. This increases the proportion of active materials (battery cells) to total volume, thereby improving energy density while maintaining necessary structural support.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If a conventional cell frame structure including an assembly of multiple plates is used, then the battery pack can fix battery cells, but the manufacturing cost increases and price competitiveness decreases

Engineering Contradiction:

Improvebattery cell fixationVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive, complex multi-plate cell frames with a simpler base plate structure that is cheaper to manufacture. This substitution maintains the essential function of supporting and fixing battery cells while significantly reducing manufacturing costs and improving price competitiveness.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If a conventional cell frame structure including an assembly of multiple plates is used, then the battery pack can support battery cells, but the assembly process complexity increases

Engineering Contradiction:

Improvebattery cell supportVSAvoidassembly process

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

By eliminating the complex multi-plate cell frame structure and retaining only the base plate, the patent reduces the number of components that need to be assembled. This simplification directly reduces assembly process complexity and improves manufacturing productivity.

Inventive Principle:

Principle #2Taking out (Extraction)

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

The proposed battery pack design achieves improved energy density, strength, price competitiveness, and fabrication efficiency by eliminating the complex cell frame structure and incorporating a cross beam unit with a cooling water channel for effective cooling.

Implementation Method 1

The cross beam unit may include a cooling water channel to cool the plurality of battery cells

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentEP4187702B1Battery pack and vehicle comprising same

Publication Date: 2025.06.04 LG ENERGY SOLUTION LTD

Figure 1
Figure 2
Figure 3

AI summary

A battery pack which is mounted in a vehicle according to an embodiment of the present disclosure includes a plurality of battery cells; a base plate to support the plurality of battery cells; and a cross beam unit which is positioned over a predetermined length along a widthwise direction of the base plate, and interposed between the plurality of battery cells in a lengthwise direction of the base plate to attach and fix the facing battery cells in the lengthwise direction.