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This paper describes a high-capacity lithium-ion battery pack that was newly developed for use in global mass production of the Nissan LEAF electric vehicle. The mass-market Nissan LEAF was launched in December 2010, and mass production began on a global scale in 2012. This development is in line with the Nissan Green Program 2010, a medium-term environmental action plan under which the diffusion of zero-emission cars is being promoted. The lithium-ion battery is one of the key technologies of electric vehicles (EVs). The battery pack accounts for a large proportion of the EV body size, weight and cost. Therefore, achieving a smaller, lighter and less expensive battery pack suitable for global mass production on a scale comparable to vehicle mass production will be an important factor in supporting widespread diffusion of EVs. The newly developed battery pack cuts the weight and costs significantly as a result of simplifying the structures of the battery module and battery pack.