Aerospace Battery Assembly Layout for High-Density Power Transfer

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Solution Overview

Problem

Battery assemblies for aerospace vehicles face challenges in achieving high power density and efficient power delivery while minimizing weight and conductive resistance due to additional wiring.

Innovation Solution

A battery assembly design featuring stacked groups of battery cells connected by group connectors and linear arrangement connectors, with optimized electrical pathways and structural rigidity, including multi-thread wires and binding elements for even load distribution and efficient power transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If power demands grow to increase battery capacity, then power delivery capability is improved, but weight and conductive resistance increase

Engineering Contradiction:
Improvepower delivery capabilityVSAvoidbattery weight
Core Design Contradiction:
PowerVSWeight of moving object

Solution Approach 1:

The battery assembly is segmented into multiple battery cell groups arranged in parallel arrays. Each group contains multiple battery cells connected in series, and the parallel arrangement allows power to be delivered through multiple simultaneous pathways. This segmentation enables the system to achieve high power delivery capability without requiring a single large-capacity battery that would be excessively heavy, thereby resolving the contradiction between power delivery and weight.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Multiple battery cell groups are merged into a unified parallel arrangement where all groups contribute to power delivery simultaneously. The collectors combine the output from multiple groups, creating a consolidated high-power output. This merging approach allows the system to achieve the power delivery capability of a large battery while using multiple smaller, lighter battery groups, thus reducing overall weight compared to a single large-capacity battery.

Inventive Principle:
Principle #5Merging (Combining)

2Power

If additional conductive wiring is added to meet higher power demands, then power delivery capability is improved, but conductive resistance increases

Engineering Contradiction:
Improvepower delivery capabilityVSAvoidconductive resistance
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

The electrical connection system is segmented into multiple parallel pathways, with each pathway containing conductive wiring connecting battery cells within a group. By distributing current across multiple parallel pathways rather than using a single high-current pathway, the conductive resistance is reduced according to the parallel resistance principle. This segmentation of the electrical architecture allows high power delivery while minimizing energy loss through resistance.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Multiple conductive pathways are merged into parallel connections at the collectors, where the equivalent resistance of parallel conductors is lower than any individual conductor. This merging of multiple low-resistance pathways creates a high-capacity power delivery system with reduced overall conductive resistance, enabling high power output while minimizing energy loss.

Inventive Principle:
Principle #5Merging (Combining)

3Weight of moving object

If battery cell density is increased to reduce weight, then weight is reduced, but power delivery efficiency may be compromised

Engineering Contradiction:
Improvebattery weightVSAvoidpower delivery efficiency
Core Design Contradiction:
Weight of moving objectVSPower

Solution Approach 1:

The battery system is segmented into multiple groups of battery cells, with each group containing a manageable number of cells arranged in series. This segmentation allows for optimized cell density within each group while maintaining efficient electrical connections. The parallel arrangement of multiple groups ensures that power delivery efficiency is maintained through distributed current pathways, preventing the efficiency loss that might occur in a densely packed single-array configuration.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The battery cells are arranged in a three-dimensional configuration with multiple groups positioned in parallel arrays rather than a single linear arrangement. This dimensional reorganization allows for increased cell density while maintaining short current pathways and efficient thermal management. The parallel array structure enables power to be delivered through multiple spatial pathways, preserving delivery efficiency even as overall cell density increases to reduce weight.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

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 design enhances battery cell density and power transfer efficiency, supporting large capacity and reducing electrical resistance, thereby improving the performance of aerospace vehicles.

Implementation Method 1

each group connector connects cathodes of a first battery cell group to anodes of a second battery cell group

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

a linear arrangement connector configured to connect the first linear arrangement to the second linear arrangement

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS12476327B2Battery assembly for aerospace vehicles
Publication Date: 2025.11.18 DRONENX LLC D B A UPGRADE ENERGY
  • US12476327B2 patent drawing
  • US12476327B2 patent drawing
  • US12476327B2 patent drawing

AI summary

Disclosed are methods and systems for aerospace vehicle batteries. For instance, a battery assembly may include a first and second battery assembly terminals; a plurality of battery cells, the plurality of battery cells being arranged in groups, each group of battery cells having a stacked arrangement of n by m battery cells orientated in a same direction, n being at least two and m being at least two; a first subset of the groups form a first linear arrangement arranged end-to-end in a first direction; and a second subset of the groups form a second linear arrangement arranged end-to-end in a second direction; a plurality of group connectors, each being configured to connect two respective battery cell groups; and a linear arrangement connector configured to connect the first linear arrangement to the second linear arrangement.