Square-Tube Battery Pack Structure for Stable Module Compression

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Solution Overview

Problem

Conventional battery packs face challenges in achieving compression stability and simplified module fixing structures, particularly in high-capacity configurations required for commercial vehicles, where space constraints and collision safety are critical.

Innovation Solution

A battery pack design utilizing a simplified structure of square tubes for fixing battery modules, including longitudinal, vertical, and horizontal square tubes arranged to provide comprehensive support and stability, with a heat sink and insulator system for cooling, and a method for manufacturing this configuration to enhance compression stability and weight reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If battery modules are arranged in multiple layers to increase capacity, then the energy storage capacity is improved, but the structural complexity and difficulty of fixing modules increases

Engineering Contradiction:

Improvebattery capacityVSAvoidmodule fixing structure

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The fixing structure is segmented into three independent directional components: longitudinal square tubes (left-right direction), vertical square tubes (vertical direction), and horizontal square tubes (front-rear direction). Each set of tubes independently fixes battery modules along its specific axis, allowing the complex multi-layer module arrangement to be managed through simple, directional fixing elements rather than a monolithic complex structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a three-dimensional tube framework that extends in three perpendicular directions (longitudinal, vertical, horizontal) to fix battery modules arranged in multiple layers. This spatial dimensionality approach allows modules to be securely positioned in complex multi-layer configurations while maintaining structural simplicity through the regular geometric pattern of the square tubes.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Stability of the object's composition

If a complex fixing structure is used to secure multi-layer battery modules, then the compression stability is improved, but the device complexity increases

Engineering Contradiction:

Improvecompression stabilityVSAvoidfixing structure

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

Each directional set of square tubes provides localized fixing quality optimized for its specific orientation: longitudinal tubes provide stability along the left-right axis, vertical tubes provide support in the vertical direction, and horizontal tubes provide fixation in the front-rear direction. This localized optimization along each axis collectively achieves comprehensive compression stability without requiring a globally complex structure.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The fixing structure combines three different directional tube components (longitudinal, vertical, horizontal) into a composite framework system. Each tube type contributes its specific directional strength, and their combination creates a composite structural system that achieves superior compression stability in all directions while maintaining the simplicity of individual tube components.

Inventive Principle:

Principle #40Composite materials

3Strength

If traditional fixing structures are used for high-capacity battery packs, then the structural strength is maintained, but the weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidbattery pack weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent replaces traditional complex mechanical fixing systems (such as multiple brackets, bolts, and support plates) with a simplified square tube framework system. The square tubes provide structural strength through their geometric shape and spatial arrangement, eliminating the need for numerous separate mechanical fastening components and reducing overall weight while maintaining equivalent or superior structural strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution improves compression stability and reduces weight while maintaining price competitiveness by using a simplified square tube structure to fix battery modules, ensuring high crush safety and efficient cooling in compact configurations.

Implementation Method 1

a heat sink and insulator system for cooling

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

liquid refrigerant flows

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

a heat sink and insulator system for cooling

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS12261314B2Battery pack and manufacturing method thereof

Publication Date: 2025.03.25 LG ENERGY SOLUTION LTD

AI summary

Discussed is a battery pack having a simplified structure and a method for manufacturing the same. The battery pack includes: an upper case and a lower case; a battery module stack in which battery modules are stacked between the upper case and the lower case; a longitudinal square tube mounted on the battery module stack; a vertical square tube mounted on the battery module stack; and a horizontal square tube mounted on the battery module stack.