Integrated Battery Module Structure for Lighter Cell Block Protection

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Solution Overview

Problem

Conventional battery modules with expandable structures face complexity, increased weight, and prolonged production processes due to the need for separate insulating covers and end plates for each cell block, complicating the assembly and increasing the module's weight.

Innovation Solution

A battery module design that integrates a first and second cell block assembly with a module frame and an upper plate, eliminating the need for separate end plates and insulating covers, and incorporating a thermal conductive resin layer and cooling plate for improved cooling and reduced weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate insulating covers and end plates are provided for each cell block assembly, then insulation and protection are ensured, but the structure becomes complicated and weight increases

Engineering Contradiction:

Improveinsulation and protectionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the insulating cover and end plate into a single integrated upper plate that covers multiple cell block assemblies. This unified structure performs both insulation and protection functions simultaneously, eliminating the need for separate components and simplifying the overall module structure while maintaining reliability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The upper plate is designed as a multi-functional component that simultaneously provides insulation, physical protection, and structural support for multiple cell block assemblies. This universal component replaces several specialized parts, reducing complexity while ensuring comprehensive protection and insulation

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate insulating covers and end plates are provided for each cell block assembly, then insulation and protection are ensured, but the production process is lengthened

Engineering Contradiction:

Improveinsulation and protectionVSAvoidproduction process efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

By merging the insulating cover and end plate into a single upper plate component, the number of assembly steps is reduced. The integrated design allows for fewer parts to be handled, stored, and installed during production, thereby streamlining the manufacturing process and improving productivity while maintaining the necessary insulation and protection functions

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If conventional end plate and insulating cover structure is applied to expandable battery module, then each cell block is protected, but the weight of the battery module increases

Engineering Contradiction:

Improvecell block protectionVSAvoidbattery module weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent merges multiple protective components (insulating covers and end plates) into a single integrated upper plate structure that protects multiple cell block assemblies simultaneously. This consolidation reduces the total material usage and component weight while maintaining comprehensive protection for all cell blocks, thereby reducing the overall battery module weight without compromising reliability

Inventive Principle:

Principle #5Merging (Combining)

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 design simplifies the structure, reduces weight, enhances assembly efficiency, and lowers production costs by integrating components, while ensuring insulation and effective cooling.

Implementation Method 1

a thermal conductive resin layer and a cooling plate, wherein the thermal conductive resin layer is formed on front and rear lower ends of the first cell block assembly and the front and rear lower ends of the second cell block assembly

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS12597672B2Battery module and battery pack including the same

Publication Date: 2026.04.07 LG ENERGY SOLUTION LTD

AI summary

A battery module includes first and second cell block assemblies including a battery cell stack and a busbar frame mounted onto front and rear surfaces of the battery cell stack; a module frame that houses the first and second cell block assemblies and is opened in front and rear directions; and an upper plate that covers the upper side surface and front and rear surfaces of the first cell block assembly and the upper side surface and front and rear surfaces of the second cell block assembly. The first and second cell block assemblies are arranged in a direction in which the busbar frames mounted onto the first and second cell block assemblies face each other. The upper plate couples to the bottom part of the module frame between the first and second cell block assemblies and at front and rear sides of the first and second cell block assemblies.