Integrated Battery Pack Housing for Higher Energy Density

Solution Overview

Problem

Conventional battery packs have a complex structure with multiple components, which reduces energy density, increases manufacturing complexity, and raises costs.

Innovation Solution

A battery pack design that integrates multiple battery cells directly into a pack housing, eliminating the need for a separate module case, and includes a filler to prevent electrical shorts and a reinforcing member to enhance structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If both module case and pack housing are included in the battery pack structure, then structural support and component protection are improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvestructural supportVSAvoidnumber of components

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the module case and pack housing into a single integrated pack housing structure. The pack housing directly accommodates multiple battery cells without requiring a separate module case, thereby reducing the number of components while maintaining structural support through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

2Strength

If both module case and pack housing are included in the battery pack structure, then structural support and component protection are improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural supportVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent merges the module case and pack housing into a single integrated pack housing structure. The pack housing directly accommodates multiple battery cells without requiring a separate module case, thereby reducing the number of components while maintaining structural support through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If multiple components are used in the battery pack, then structural integrity and protection are improved, but energy density decreases

Engineering Contradiction:

Improvestructural integrityVSAvoidenergy density

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The patent merges the module case and pack housing into a single integrated pack housing structure. The pack housing directly accommodates multiple battery cells without requiring a separate module case, thereby reducing the number of components while maintaining structural support through the integrated design.

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

This design simplifies the manufacturing process, reduces the number of components, increases energy density, and lowers manufacturing costs while preventing electrical shorts and structural deformations.

Implementation Method 1

a lower portion of each of the plurality of battery cells is bonded to an inner surface of the pack housing

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentUS12322817B2Battery pack, and electronic device and vehicle including the same

Publication Date: 2025.06.03 LG ENERGY SOLUTION LTD

AI summary

A battery pack includes a plurality of battery cells elongated to be oriented in a vertical direction and having a pair of electrode terminals located at an upper portion thereof, the plurality of battery cells being arranged in at least one horizontal direction; and a pack housing having an accommodation space in which the plurality of battery cells are accommodated and configured such that a lower portion of each of the plurality of battery cells is bonded to an inner surface of the pack housing.