Aircraft Battery Intumescent Layer for Thermal Runaway Containment
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Solution Overview
Problem
Lithium-type batteries used in aircraft face challenges with uncontrolled thermal runaway and breach of the battery casing due to external impacts, leading to hazardous gas and fire releases, which existing solutions like self-healing polymers and intumescent materials fail to adequately mitigate, especially under high temperatures.
Innovation Solution
A battery design featuring a functional layer with an intumescent material that forms a fireproof and thermally insulating barrier within the casing, capable of containing flames and heat, and redirecting gases through a controlled venting system, even after a breach, without adding significant weight or requiring additional protection mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional ballistic protection (bullet-resistant armor) is used to protect the battery casing from external impacts, then the battery's resistance to external impacts is improved, but the weight of the battery increases significantly
Solution Approach 1:
The patent applies beforehand cushioning by providing a functional layer with intumescent material inside the battery casing that activates upon impact. This layer is prepared in advance to cushion and contain the effects of external impacts, ballistics threats, or thermal runaway events, preventing direct damage to battery cells without requiring heavy external armor protection
2Reliability
If self-healing polymers are used to seal breaches in the battery casing, then the sealing capability is improved, but the material degrades at high temperatures during thermal runaway
Solution Approach 1:
The patent applies parameter changes by using intumescent material that undergoes a temperature-triggered transformation. When exposed to high temperatures during thermal runaway, the intumescent material expands and forms a charred barrier, changing its physical parameters to provide effective sealing and containment precisely when needed, unlike self-healing polymers that degrade at such temperatures
3Reliability
If the battery casing is made breach-resistant to prevent thermal runaway, then the containment capability is improved, but the ability to vent hot gases in a controlled manner is reduced
Solution Approach 1:
The patent applies the intermediary principle by introducing a functional layer with intumescent material as a mediator between the battery cells and the external environment. This layer can contain breaches and control the release of hot gases, acting as an intermediate barrier that provides both containment and controlled venting capabilities, preventing uncontrolled release while allowing safe gas evacuation
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 effectively contains hazardous gases and heat within the battery casing, preventing uncontrolled releases and ensuring safety, while maintaining a low weight profile, thus addressing the limitations of traditional ballistic protection methods.
Implementation Method 1
The functional layer comprises an intumescent material that, in case of a breach of the battery casing, is adapted to ensuring flame containment within the interior volume and mitigation of uncontrolled heat and gas emission from the interior volume through the breach of the battery casing
Implementation Method 2
The gas evacuation provision may prevent an increase in pressure inside the battery casing, thereby preventing an explosion of the battery
Data Source
AI summary
A battery for an aircraft. The present embodiments further relate to an aircraft with at least one such battery. The battery may include a battery casing with a casing wall that forms an interior volume, a plurality of battery cells that is arranged in the interior volume, and a functional layer that is arranged at the casing wall between the plurality of battery cells and the battery casing. The functional layer may include an intumescent material that, in case of a breach of the battery casing, is adapted to ensuring flame containment within the interior volume and mitigation of uncontrolled heat and gas emission from the interior volume through the breach of the battery casing.