Aircraft Battery Module Cell Tubes for Fire Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The development of electric and hybrid aircraft faces challenges due to the need for unique design elements and stringent certification standards, which have hindered commercial viability and increased costs and time due to safety concerns, particularly with battery systems that can lead to catastrophic failures from overheating or fires.
Innovation Solution
A battery module design featuring cell tubes with spacers for thermal and electrical isolation, an exhaust channel to divert fires, and a circuit board assembly for monitoring and controlling battery cells, allowing for safer and more efficient power management in electric aircraft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery cells are enclosed by cell holders along their whole length, then the battery cells are protected, but the chassis becomes heavy and bulky
Solution Approach 1:
The patent divides the battery cell enclosure into discrete tube segments rather than continuous holders. Each tube is a separate component that can be individually positioned and removed, reducing overall material usage and weight while maintaining protection at critical locations.
Solution Approach 2:
The patent extracts the essential protective function from continuous enclosures and implements it through discrete tubes positioned at specific locations. This selective approach removes unnecessary material while preserving the core safety function of protecting battery cells from external damage and thermal runaway propagation.
2Reliability
If battery cells are enclosed by cell holders along their whole length, then the battery cells are protected, but the chassis becomes bulky
Solution Approach 1:
The patent segments the enclosure system into discrete tubes rather than using continuous holders, allowing for compact arrangement and reduced overall volume. The segmented structure enables better space utilization within the aircraft while maintaining protective coverage.
Solution Approach 2:
The patent extracts only the essential protective segments and positions them strategically around battery cells, removing the need for continuous enclosures. This reduces the overall volume occupied by the battery system while maintaining adequate protection.
3Adaptability or versatility
If new aircraft designs are developed for electric or hybrid operation, then functionality is improved, but extensive testing is required which increases cost and time
Solution Approach 1:
The patent incorporates safety features such as fire diverters and thermal management systems during the initial design phase, allowing certification authorities to verify safety upfront. This preliminary integration of safety mechanisms reduces the need for extensive post-development testing and accelerates the certification process.
Solution Approach 2:
The patent converts potential harmful effects (heat, fire) into manageable aspects by designing fire diverters that channel thermal energy away from critical areas. This proactive safety design allows certification to proceed more efficiently by demonstrating inherent safety features rather than requiring extensive testing to prove safety.
4Reliability
If fire diverters are added to channel heat away from battery cells, then safety is improved, but device complexity increases
Solution Approach 1:
The patent merges the fire diverter function with existing structural components of the battery module, such as integrating heat channels into the housing or support structures. This combination approach adds safety functionality without proportionally increasing overall device complexity.
Solution Approach 2:
The patent designs components to serve multiple functions: structural support, thermal management, and fire diversion. By making components multi-functional, the patent reduces the need for separate dedicated fire safety components, thereby limiting the increase in device complexity while maintaining improved safety.
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 reduces the risk of fire spread among battery cells, enhances safety, and streamlines certification processes, making electric aircraft production more cost-effective and efficient by preventing chain reactions and evenly distributing heat across battery cells.
Implementation Method 1
said first spacer providing thermal and electrical isolation between the corresponding battery cell and the first conductive plate
Implementation Method 2
said first spacer providing thermal and electrical isolation between the corresponding battery cell and the first conductive plate
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
1. A battery module (800), comprising: a plurality of battery cells (8120); a plurality of cell tubes (812, 813, 814) configured to accommodate the plurality of battery cells (8120) within the plurality of cell tubes so that individual of the plurality of battery cells are positioned within individual of the plurality of cell tubes, each battery cell having a first electric pole and a second electric pole, a first conductive plate (862) which mutually electrically connects the first poles of each of the plurality of battery cells, said first conductive plate comprising a plurality of first holes (868) so that individual of the plurality of cell tubes are facing individual of the plurality of first holes, a plurality of first spacers (863), each first spacer being mounted in one of said first holes and configured to support one said cell tube and one said battery cell, said first spacer providing thermal and electrical isolation between the correspond battery cell and the first conductive plate.