Battery module and electric aircraft based on phase change material and air cooling system

Abstract

The present invention discloses a battery module and electric aircraft based on phase change material and air-cooled heat dissipation system, including a module shell frame and a heat-conducting plate; the module shell frame is composed of four side panels fixedly connected; a plurality of heat-conducting plates are arranged in parallel and spaced apart between the module shell frame, and an alternating distribution of battery cell compartments, phase change material compartments and heat dissipation ducts is formed between adjacent heat-conducting plates; the battery cell compartment is used to accommodate battery cells in direct contact with the heat-conducting plates; the phase change material compartment is filled with phase change material and is heat-conductingly connected to the battery cell through the heat-conducting plate; the heat dissipation duct is connected to the external air-cooling channel. The present invention alternately stacks the phase change material compartments and the air-cooled heat dissipation ducts to separate and form a three-level heat conduction path of battery cell-phase change material-air duct, achieving a balance between efficient absorption of short-term high-power heat generation and continuous heat dissipation; the takeoff phase relies on the phase change material to quickly absorb heat, and the cruising phase uses high-speed airflow to remove heat and promote the solidification and regeneration of the phase change material, thereby solving the problem of continuous energy consumption of the system.

Description

Technical Field

[0001] The present invention belongs to the technical field of power battery thermal management, and specifically relates to a battery module and an electric aircraft based on phase change materials and an air-cooled heat dissipation system. Background Art

[0002] With the rapid development of electric aircraft, thermal management of their power battery systems is gaining increasing attention. As the core energy supply unit, the effectiveness of the thermal management system of the battery module is directly related to the safety, endurance, and overall performance of the aircraft.

[0003] In existing technologies, battery thermal management systems mainly use liquid cooling solutions, or combine them with air cooling and phase change materials. Although liquid cooling systems can provide high heat dissipation efficiency by circulating coolant for forced convection heat exchange, they have the following drawbacks:

[0004] 1. The liquid cooling system requires complex piping, pumps, compressors, and heat exchangers, significantly increasing the overall weight of the battery module. This is particularly detrimental to lightweight electric aircraft, directly affecting the aircraft's payload and range.

[0005] 2. The liquid cooling system relies on the continuous operation of equipment such as compressors to maintain coolant circulation, resulting in a decrease in the effective utilization rate of electrical energy. Especially during the long-duration cruise phase, the continuous energy consumption increases the energy burden of the aircraft.

[0006] 3. The flight conditions of electric aircraft are characterized by phased operation. During takeoff, the battery experiences a short, high-power discharge, generating heat, while the cooling demand drops sharply during level flight and cruising. Existing liquid cooling systems must maintain high power for extended periods to cope with peak heat loads, and are unable to dynamically adjust cooling strategies based on operating conditions, resulting in energy waste. Relying solely on air cooling systems would be unable to quickly absorb and dissipate the large amounts of heat during takeoff, easily leading to battery cell overheating.

[0007] In recent years, some research has attempted to incorporate phase change materials into battery thermal management, leveraging their latent heat to absorb transient high heat fluxes. However, existing designs incorporating phase change materials are often coupled with liquid cooling systems, failing to effectively address the inherent weight and energy consumption issues of liquid cooling. Furthermore, the low thermal conductivity and insufficient regeneration efficiency of phase change materials limit their application in dynamic cooling scenarios. Summary of the Invention

[0008] The main purpose of the present invention is to provide a battery module based on phase change material and air-cooled heat dissipation system with a light heat dissipation system and fast heat dissipation during takeoff, as well as an electric aircraft equipped with such a battery module.

[0009] The battery module based on phase change material and air cooling and heat dissipation system provided by the present invention includes a module shell frame and a heat conduction plate; the module shell frame is composed of four side panels fixedly connected; multiple heat conduction plates are arranged in parallel and at intervals between the module shell frame, and battery cell compartments, phase change material compartments and heat dissipation ducts are alternately formed between adjacent heat conduction plates; the battery cell compartments are used to accommodate battery cells that are in direct contact with the heat conduction plates; the phase change material compartments are filled with phase change material and are thermally connected to the battery cells through the heat conduction plates; and the heat dissipation ducts are connected to the external air cooling channel.

[0010] In one embodiment of the above battery module, the module housing frame includes a first side surround, a second side surround, a third side surround and a fourth side surround which are sequentially connected end to end.

[0011] In one embodiment of the above battery module, the heat conducting plates are arranged in parallel and spaced apart between the first side enclosure and the third side enclosure that are opposite to each other, and mounting ears are provided on the outer sides of the first side enclosure and the third side enclosure.

[0012] In one embodiment of the above-mentioned battery module, both ends of the heat conducting plate are fixedly connected to the inner side walls of the second and fourth side enclosures respectively arranged opposite to each other to form the main load-bearing frame of the module; exhaust grooves are provided at the bottom of the second and fourth side enclosures.

[0013] In one embodiment of the above battery module, the phase change material is a paraffin-based composite material doped with a thermally conductive filler, and the thermally conductive filler includes foamed aluminum or highly thermally conductive carbon foam.

[0014] In one embodiment of the above battery module, the contact surface between the battery core and the heat conducting plate is coated with a thermal grease layer.

[0015] In one embodiment of the above battery module, the bottom of the module housing includes a double-layer structure of an inner bottom plate and an outer bottom plate, the inner bottom plate and the outer bottom plate are spaced apart to form a bottom heat dissipation duct, and the inner bottom plate is higher than the outer bottom plate.

[0016] In one embodiment of the above battery module, the phase change material compartment is sealed by a heat conducting plate, a cover plate and an inner bottom plate.

[0017] In one embodiment of the battery module, a plurality of ventilation holes are provided at the bottom of each of the heat conducting plates, and the heat dissipation duct is connected to the heat dissipation duct at the bottom through the ventilation holes.

[0018] An electric aircraft equipped with the above-mentioned battery module, wherein the battery module is installed in the wing of the electric aircraft, the heat dissipation duct of the battery module is connected to the air flow path of the aircraft's air cooling channel, and an active cooling component is provided on the upstream side of the air cooling channel. The active cooling component is configured to inject refrigerant into the air cooling channel under extreme heat load conditions.

[0019] The beneficial effects of the present invention are as follows:

[0020] 1. Phase change material compartments and air cooling ducts are alternately stacked and separated by heat conducting plates to form a three-level heat conduction path: battery cell-phase change material-air duct. This achieves a balanced and efficient absorption of short-term, high-power heat generation while maintaining continuous heat dissipation. During takeoff, the phase change material rapidly absorbs heat. During cruise, high-speed airflow removes heat and promotes solidification and regeneration of the phase change material, thus solving the problem of continuous energy consumption in traditional liquid cooling systems.

[0021] 2. The heat conducting plate serves as the main load-bearing frame of the battery module, simultaneously fulfilling the triple functions of heat conduction, structural support, and air duct partitioning, replacing the complex piping of the liquid cooling system and significantly reducing the system weight;

[0022] 3. It adopts a double-layer structure design of inner and outer bottom plates, with a heat dissipation duct reserved at the bottom and vertical airflow guidance through vents and exhaust slots to enhance air cooling efficiency;

[0023] 4. The aircraft is equipped with active cooling components upstream of the air cooling channel to achieve enhanced heat dissipation under extreme working conditions through refrigerant injection, forming a hierarchical thermal management strategy. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present invention.

[0025] Figure 2 for Figure 1 Schematic diagram of the top view structure.

[0026] Figure 3 for Figure 2 Cross-sectional view at AA in the middle.

[0027] Figure 4 for Figure 1 A schematic structural diagram of the second side surround or the fourth side surround.

[0028] Figure 5 for Figure 1 Schematic diagram of the structure of the heat conduction plate.

[0029] Figure 6 Schematic diagram of the airflow direction of an electric aircraft equipped with a battery module. DETAILED DESCRIPTION

[0030] The following will be combined with the accompanying drawings in the embodiments of the present invention to clearly and completely describe the relevant technical solutions. Obviously, the embodiments described are only some embodiments, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0031] Combine Figure 1 、 Figure 2 As can be seen from the figure, the battery module based on phase change material and air cooling and heat dissipation system disclosed in this embodiment includes a side panel 1, a heat conducting plate 2, a battery cell 3, a phase change material 4, a heat dissipation duct 5, a cover plate 6, an inner bottom plate 7 and an outer bottom plate 8.

[0032] The side panels 1 comprise four components: a first side panel 11, a second side panel 12, a third side panel 13, and a fourth side panel 14. Each component is connected end-to-end by welding or screwing to form the module housing frame. The side panels can be constructed as plates or boxes, but this embodiment does not limit this.

[0033] The first side panel 11 and the third side panel 13 are arranged opposite to each other, and the outer side walls thereof are both provided with mounting ears 15 for fixing the module to the wing, fuselage or power nacelle of the aircraft.

[0034] like Figure 4 As shown, the second side panel 12 is arranged opposite to the fourth side panel 14 , and an exhaust slot 16 is provided at the bottom thereof for guiding the airflow in the heat dissipation duct 5 .

[0035] Multiple heat-conducting plates 2 are arranged in parallel and spaced apart between the first side panel 11 and the third side panel 13, with their ends fixedly connected to the inner walls of the second side panel 12 and the fourth side panel 14. Cell compartments, phase change material compartments, and cooling ducts 5 are alternately formed between adjacent heat-conducting plates.

[0036] The battery cell compartment is formed by two heat-conducting plates 2 to accommodate the battery cell 3; the two large side surfaces of the battery cell are in direct contact with the heat-conducting plates to maximize the heat dissipation contact area; the contact surface is coated with thermal grease to reduce the contact thermal resistance caused by the installation gap and enhance the thermal conductivity.

[0037] The phase change material compartments are located on both sides of the battery cell compartment and are filled with phase change material 4.

[0038] The primary function of the phase change material is to rapidly and massively absorb heat dissipated by the battery cells 3 during takeoff and climb, through a solid-liquid phase transition, to maintain the cells within their safe operating temperature range. Simultaneously, during level flight and cruise, it continues to function as a heat absorber and thermal conductor. Therefore, the phase change material must have an appropriate phase change temperature and a high latent heat of change.

[0039] Phase change materials can be selected from alkanes, polyethylene glycol (PEG), paraffin (PW), lauric acid (LA), stearic acid (SA) and other materials with good stability, high latent heat, easy acquisition and low cost.

[0040] This embodiment uses paraffin as the phase change material. However, paraffin as a phase change material has the disadvantage of low thermal conductivity. To increase the thermal conductivity of the phase change material, this embodiment fills the paraffin with a thermally conductive filler, which includes foamed aluminum or highly thermally conductive carbon foam.

[0041] The phase change material compartment is sealed by the heat conducting plate 2, the cover plate 6 and the inner bottom plate 7 to prevent leakage of the phase change material. The battery cell compartment has no cover plate on top and is not sealed because it needs to connect electrode lead wires, etc.

[0042] The heat dissipation duct 5 is located outside the phase change material compartment, is separated by the heat conducting plate 2, and is connected to the external air cooling channel.

[0043] The outer bottom plate 8 closes the bottom end of the module housing frame formed by the enclosure 1; the inner bottom plate 7 is higher than the outer bottom plate, and the bottom heat dissipation duct 51 is formed between the inner bottom plate and the outer bottom plate.

[0044] like Figure 5 As shown, a plurality of vents 21 are provided at the bottom of each heat conducting plate 2 to vertically guide the airflow in the heat dissipation duct 5 into the bottom heat dissipation duct and finally discharge the airflow through the exhaust slots 16 of the second side panel and the fourth side panel.

[0045] Working principle of the heat dissipation structure of the battery module:

[0046] 1. Takeoff and climb phase:

[0047] During this phase, the operating time is small, and the aircraft's overall power and heat generation are high. During this phase, the battery cells 3 discharge at high power, generating a large amount of heat. This heat is transferred to the phase change material 4 via the heat transfer plates 2 on both sides of the battery cells. The phase change material rapidly absorbs the heat through its solid-liquid phase transition. Simultaneously, the heat absorbed by the phase change material is transferred via the heat transfer plates 2 to the high-speed airflow in the heat dissipation duct 5, achieving heat exchange.

[0048] 2. During level flight cruise:

[0049] During this phase, the operating time accounts for a large proportion, and the aircraft's overall power and heat generation are low. During this phase, the phase change material has already undergone a large phase change. On the one hand, the phase change material, acting as a heat-absorbing and heat-conducting material, continues to absorb the small-power heat generated by the battery cells 3. On the other hand, the phase change material is cooled by the high-speed airflow in the heat dissipation duct 5 and gradually resolidifies into a solid state, resuming its ability to absorb large amounts of heat in a short period of time, ready for operation in the next phase.

[0050] 3. Cooling air duct:

[0051] The high-speed airflow in the heat dissipation duct 5 after heat exchange flows into the bottom heat dissipation duct 51 through the vents 21 below the heat conducting plate 2, and finally is guided out of the battery module structure through the exhaust slots 16 opened at the bottom of the second side panel 12 and the fourth side panel 14.

[0052] like Figure 6As shown, this embodiment also provides an electric aircraft equipped with the above-mentioned battery module, wherein the battery module is installed in the wings, fuselage, or power nacelle of the electric aircraft. The heat dissipation duct 5 of the battery module is connected to the air flow path of the aircraft's air cooling channel 9 to ensure the input and exhaust of air in the heat dissipation duct.

[0053] The battery module of this embodiment is installed in the wing of the electric aircraft.

[0054] An active cooling assembly 10 is installed upstream of the cooling duct 9 and is integrated with the wing or nacelle where the battery modules are located. This assembly provides refrigerant to the cooling duct and heat dissipation duct. Under extreme heat loads, refrigerant is injected into the cooling duct to enhance heat dissipation.

[0055] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although detailed descriptions have been provided with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or substitute equivalents for some of the technical features. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. A battery module based on phase change materials and an air-cooled heat dissipation system, characterized by: It includes a module shell frame and a heat conduction plate; the module shell frame is composed of four side panels fixedly connected; a plurality of heat conduction plates are arranged in parallel and at intervals between the module shell frame, and battery cell compartments, phase change material compartments and heat dissipation ducts are formed alternately between adjacent heat conduction plates, the phase change material compartments are located on both sides of the battery cell compartments, and the heat dissipation ducts are located outside the phase change material compartments; the battery cell compartments are used to accommodate battery cells that are in direct contact with the heat conduction plates; the phase change material compartments are filled with phase change material and are heat-conductingly connected to the battery cells through the heat conduction plates; the heat dissipation duct is connected to an external air cooling channel; the bottom of the module shell includes a double-layer structure of an inner bottom plate and an outer bottom plate, the inner bottom plate and the outer bottom plate are spaced apart to form a bottom heat dissipation duct, and the height of the inner bottom plate is higher than the outer bottom plate; a plurality of air vents are provided on the bottom of the heat conduction plates, and the heat dissipation duct is connected to the bottom heat dissipation duct through the air vents.

2. The battery module based on phase change material and air cooling system according to claim 1, characterized in that: The module housing frame includes a first side surround, a second side surround, a third side surround and a fourth side surround which are connected end to end in sequence.

3. The battery module based on phase change material and air cooling system according to claim 2, characterized in that: The heat conducting plates are arranged in parallel and at intervals between the first side surround and the third side surround which are arranged opposite to each other, and mounting ears are provided on the outer sides of the first side surround and the third side surround.

4. The battery module based on phase change material and air cooling system according to claim 2, characterized in that: The two ends of the heat conducting plate are respectively fixedly connected to the inner side walls of the second side enclosure and the fourth side enclosure which are arranged opposite to each other to form the main load-bearing frame of the module; the bottoms of the second side enclosure and the fourth side enclosure are provided with exhaust grooves.

5. The battery module based on phase change material and air cooling system according to claim 1, characterized in that: The phase change material is a paraffin-based composite material doped with a thermally conductive filler, and the thermally conductive filler includes foamed aluminum or highly thermally conductive foamed carbon.

6. The battery module based on phase change material and air cooling system according to claim 1, characterized in that: The contact surface between the battery core and the heat conducting plate is coated with a thermal conductive silicone grease layer.

7. The battery module based on phase change material and air cooling system according to claim 1, characterized in that: The phase change material chamber is sealed by a heat conducting plate, a cover plate and an inner bottom plate.

8. An electric aircraft equipped with the battery module according to any one of claims 1 to 7, characterized in that: The battery module is installed in the wing of the electric aircraft, and the heat dissipation duct of the battery module is connected to the air flow path of the aircraft's air cooling channel. An active cooling component is provided on the upstream side of the air cooling channel, and the active cooling component is configured to inject refrigerant into the air cooling channel under extreme heat load conditions.

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