Aircraft Battery Cold Plate Assembly for Weight and Heat Control
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Solution Overview
Problem
Conventional rotorcraft designs face challenges due to the size and weight of batteries, which increase the fuselage size and weight, and create drag during flight operations, as multiple batteries are required to power electric or hybrid propulsion systems.
Innovation Solution
A battery assembly is integrated into the aircraft using a cold plate secured to longitudinally-extending beams, where the battery is mounted on an upper side of the cold plate for heat transfer to a cooling fluid through fluid channels, and stiffeners provide structural support and compartmentalization for battery packs, eliminating the need for separate supporting structures and cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If multiple batteries are stored in the fuselage of the rotorcraft, then the electric propulsion system can be powered, but the fuselage size and weight increase
Solution Approach 1:
The patent combines the battery mounting structure with the aircraft airframe structure. The battery assembly is integrated into the fuselage using the existing longitudinal beams and skin panels, eliminating the need for separate supporting structures. This merging of functions reduces overall weight while maintaining the required battery capacity for electric propulsion.
2Use of energy by moving object
If multiple batteries are stored in the fuselage of the rotorcraft, then the electric propulsion system can be powered, but the fuselage size increases
Solution Approach 1:
The aircraft skin panels and longitudinal beams serve multiple functions: they provide structural support for the fuselage and simultaneously serve as the mounting structure and cooling system for the batteries. The skin panels act as both the outer fuselage surface and the cold plate for thermal management, eliminating the need for separate battery housings and cooling systems.
3Reliability
If batteries are mounted with separate supporting structures and cooling systems, then reliable battery operation is achieved, but device complexity increases
Solution Approach 1:
The patent integrates the mounting structure and cooling system into the aircraft airframe itself. The longitudinal beams provide structural support and positioning, while the skin panels serve as the cold plate with embedded fluid channels for cooling. This eliminates separate mounting brackets, housings, and external cooling systems, reducing complexity while maintaining reliability through the aircraft's primary structure.
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 reduces the weight and size of the rotorcraft by integrating the battery assembly directly into the airframe, efficiently transferring heat and supporting the battery weight, while minimizing drag and corrosion risks, and allowing for easier maintenance.
Implementation Method 1
at least one fluid channel positioned below a lower side of the planar member and configured to receive a cooling fluid
Implementation Method 2
the battery is mounted to an upper side of the planar member for transferring heat from the battery to the cooling fluid through the planar member
Data Source
AI summary
An aircraft includes a fuselage and an airframe supporting the fuselage. The airframe includes a pair of longitudinally-extending beams. The aircraft further includes a battery assembly including a cold plate secured to the pair of longitudinally-extending beams, and a battery mounted to the cold plate.