Battery Cell Module Structure Using Aerogel and PCM Barriers

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Solution Overview

Problem

Existing battery designs suffer from poor space utilization and low power-to-weight ratios, particularly in aeronautical applications, while also being prone to cascading thermal runaway failures due to inadequate thermal management.

Innovation Solution

A battery cell module comprising flat battery cells stacked with compressible aerogel and phase change materials (PCMs) for heat absorption, along with a circuit arrangement and separation layers for thermal and mechanical protection, allowing for efficient packing and reduced risk of thermal runaway propagation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If cells are packed closely together to improve space utilization, then space utilization improves, but thermal runaway propagation risk increases

Engineering Contradiction:

Improvespace utilizationVSAvoidthermal runaway propagation risk

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent introduces aerogel layers as intermediary materials between adjacent battery cells. These aerogel layers serve as thermal barriers that physically separate cells while occupying minimal space, thereby preventing thermal runaway propagation between cells without significantly compromising space utilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies different materials with specific local properties: aerogel layers are placed specifically between adjacent cells where thermal isolation is needed, while PCM layers are positioned to absorb heat locally during thermal events. This localized application of specialized materials provides targeted thermal protection without affecting overall space utilization.

Inventive Principle:

Principle #3Local quality

2Reliability

If thermal insulation materials are added between cells to prevent thermal runaway, then thermal protection improves, but weight increases

Engineering Contradiction:

Improvethermal protectionVSAvoidmodule weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent employs aerogel, a highly porous material with extremely low density and exceptional thermal insulation properties. The aerogel layers provide effective thermal barriers between cells while contributing negligibly to the overall module weight due to their microporous structure and gas-filled voids.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent uses composite material structures combining aerogel layers with PCM layers. This composite approach creates a multi-functional thermal management system where aerogel provides insulation and PCM provides heat absorption, achieving superior thermal protection with minimal weight penalty.

Inventive Principle:

Principle #40Composite materials

3Volume of moving object

If compression is applied to pack cells tightly to improve space utilization, then space utilization improves, but cell expansion during thermal events is restricted

Engineering Contradiction:

Improvespace utilizationVSAvoidthermal event damage

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent employs dynamically responsive compression plates that can adjust their compression force. During normal operation, the plates maintain tight packing for optimal space utilization. During thermal events, the plates can expand or relax to accommodate cell expansion, preventing mechanical damage while maintaining thermal protection.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The aerogel layers are pre-positioned between cells to provide cushioning and thermal isolation before thermal events occur. These layers are designed to accommodate cell expansion during thermal events while maintaining their thermal barrier function, providing beforehand protection against both thermal propagation and mechanical damage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 enhances space utilization, improves power-to-weight ratios, and effectively mitigates thermal runaway risks by absorbing heat and providing thermal resistance, thus protecting cells from cascading failures.

Implementation Method 1

The PCM can absorb heat generated during a thermal runaway of a given battery cell, thus protecting the other battery cells

Methodology Applied

Scientific EffectHeat absorption: Latent Heat

Implementation Method 2

The compressible aerogel provides heat transfer resistance and allows for battery cell compression and expansion during thermal events

Methodology Applied

Scientific EffectHeat transfer resistance: Thermal Insulation

Data Source

PatentEP4261966A1Battery cell module and arrangement

Publication Date: 2023.10.18 VOLOCOPTER TECHNOLOGIES GMBH

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AI summary

We propose a battery cell module (10), comprising: a plurality of flat battery cells (1) arranged side by side in a stack; a layer of a compressible aerogel (17) between al least two of said battery cells (1); at least one layer of phase change material (18), PCM; a circuit arrangement with battery cell management electronics (14a) in operative connection with said plurality of battery cells (1); at least two compression plates (11) arranged on opposite sides of said stack; compression means (12) operable in a cell compression direction (CD) for to hold said stack together between said compression plates (11); and a separation layer (19) arranged between said stack and said circuit arrangement.