Aerospace Pouch Battery Structure for Thermal Runaway Containment
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Solution Overview
Problem
Aerospace batteries face risks of uncontrolled thermal events, such as fires and explosions, due to flammable components and inadequate cooling, which can lead to propagation of thermal runaway reactions.
Innovation Solution
The design incorporates a ceramic jacket surrounding pouch cell batteries, closed cell foam filling the housing to reduce free space, and flexible cold plates with cooling channels to manage temperature, along with an arc-shaped casing for pressure resistance and venting, and a retaining seat system for thermal management and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery designs are used with flammable components and standard cooling, then device complexity is reduced, but thermal runaway risk increases leading to fires and explosions
Solution Approach 1:
The battery pack is divided into multiple districts, each surrounded by its own ceramic jacket. This segmentation isolates thermal events to specific districts, preventing propagation to other districts while maintaining overall system reliability without excessive complexity.
Solution Approach 2:
The patent uses ceramic jackets (alumina-silicate or calcium magnesium silicate) combined with closed cell foam and flexible cold plates to create a composite protective system. These materials provide thermal runaway resistance while being integrated into the battery structure in a manageable way.
2Reliability
If ceramic jackets and closed cell foam are added to contain combustion, then thermal runaway risk is reduced, but weight of the battery increases
Solution Approach 1:
Protective features such as ceramic jackets and closed cell foam are applied locally where thermal runaway risk is highest (around individual districts and pouch cells) rather than uniformly across the entire battery. This provides explosion resistance while minimizing unnecessary weight addition.
Solution Approach 2:
Closed cell foam is used as a lightweight porous material that provides both structural support and thermal/combustion containment. The foam's cellular structure offers protective functions with minimal weight penalty compared to solid materials.
3Temperature
If flexible cold plates with cooling channels are integrated between pouch cells, then temperature control improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The cold plate is designed to be flexible rather than rigid, allowing it to adapt to dimensional changes in pouch cells during operation. This flexibility simplifies assembly compared to rigid cooling systems that would require precise tolerances and complex adjustment mechanisms.
Solution Approach 2:
The flexible cold plate serves multiple functions: thermal management through cooling channels, electrical isolation between pouch cells, and mechanical accommodation of cell dimensional changes. This multi-functionality reduces the need for separate components, simplifying the overall system despite the added cooling capability.
4Reliability
If arc-shaped casing is used for pressure resistance, then explosion containment improves, but manufacturing complexity increases
Solution Approach 1:
The arc-shaped (curved) casing design provides superior pressure resistance and explosion containment compared to flat designs. The curvature naturally distributes stress during thermal events, enhancing safety. The casing is formed as a single piece through stamping or molding, which avoids the need for multiple panels and complex fastening systems, thereby maintaining ease of manufacture despite the curved geometry.
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
This configuration significantly reduces the risk of thermal runaway, contains combustion, and maintains battery temperatures within safe limits, preventing explosions and enhancing the battery's operational safety and longevity.
Implementation Method 1
closed cell foam filling the housing to reduce free space
Implementation Method 2
flexible cold plates with cooling channels to manage temperature
Implementation Method 3
flexible cold plate defines a cooling channel having an inlet and an outlet
Implementation Method 4
a ceramic jacket surrounding the district
Implementation Method 5
an arc-shaped casing for pressure resistance and venting
Data Source
AI summary
An aerospace battery may include a housing and a battery pack core. The housing may include a thin dual layer casing. The battery pack core is disposed in the housing and may include at least one cell district that includes a plurality of pouch cell batteries. A ceramic material may surround the at least one cell district and a closed cell foam may fill open space between the ceramic material and the housing.