Aircraft Battery Module Layout for Lightweight Safe Maintenance
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Solution Overview
Problem
Aircraft battery systems face challenges in reducing non-useful mass for protection, which affects energy density and aerodynamics, and maintenance is complicated due to redundant structural arrangements and potential fire hazards, especially when battery packs are located beneath passengers or within wings.
Innovation Solution
The battery system is arranged with packs accessible from outside the fuselage, divided into groups on either side for even distribution and reduced complexity, using a rack mounting mechanism for easy module exchange and a thermal management system for improved safety, allowing for lightweight, high-performance, and safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery packs are enclosed in redundant structural arrangements for protection, then safety is improved, but weight increases and energy density decreases
Solution Approach 1:
The battery system is divided into modular battery packs that can be independently installed and removed. Each pack contains multiple battery modules arranged in a segmented fashion, allowing protection at the module level rather than requiring heavy enclosure for the entire system. This segmentation enables safety through modular isolation while reducing overall structural weight.
Solution Approach 2:
The battery packs are extracted from traditional enclosed locations (wings, beneath passenger compartment) and repositioned to accessible areas of the fuselage. This extraction eliminates the need for complex protective enclosures within critical structural areas, reducing weight while maintaining safety through strategic placement and modular design.
2Stability of the object's composition
If battery packs are arranged within wings or beneath passenger compartment, then structural integration is improved, but aerodynamics worsen due to thick wings and maintenance becomes difficult
Solution Approach 1:
Instead of integrating battery packs within the horizontal plane of the wings (which increases wing thickness and affects aerodynamics), the system relocates packs to the vertical dimension along the fuselage sides. This dimensional change maintains structural integration while preserving clean wing contours for optimal aerodynamics.
3Volume of stationary object
If battery modules are tightly packed for space efficiency, then volume utilization is improved, but thermal runaway propagation prevention becomes difficult requiring additional mass
Solution Approach 1:
Battery modules are arranged in segmented rows with deliberate spacing between them. This segmentation creates natural thermal isolation zones that prevent runaway propagation while maintaining high volume utilization. The modular structure allows tight packing in the longitudinal direction while preserving transverse spacing for thermal management.
Solution Approach 2:
Thermal management components and spacing structures act as intermediaries between adjacent battery modules. These elements provide thermal isolation without requiring excessive mass, enabling tight packing while preventing heat transfer that could lead to runaway propagation.
4Stability of the object's composition
If battery packs are located in inaccessible locations for structural integration, then structural stability is improved, but maintainability worsens requiring massive equipment
Solution Approach 1:
Battery packs are extracted from deeply integrated locations within the fuselage structure and repositioned to accessible areas where only the outer wall needs to be opened. This extraction maintains structural stability through proper mounting points while dramatically improving maintainability, allowing replacement without removing interior panels or using heavy equipment.
5Weight of moving object
If distributed battery packs are used throughout the aircraft, then weight distribution is improved, but device complexity increases
Solution Approach 1:
All battery packs use standardized mounting brackets, electrical connectors, and structural interfaces. This universality allows distributed placement throughout the fuselage for optimal weight distribution while reducing complexity through standardization. The same modular design and connection protocols apply to every pack, simplifying installation and maintenance despite the distributed arrangement.
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to an aircraft (10), comprising a fuselage (12), at least one pair of wings (14, 16) and a battery system, wherein the battery system comprises at least one battery pack (24), each battery pack (24) comprising a number of individual battery modules (26), which are directly or indirectly coupled to one another. The at least one battery pack (24) can be disposed between an inner structural wall (20) defining an interior space (18) of the fuselage (12) and an outer fairing wall (22) of the fuselage (12). The fuselage (12) can be provided with a rack mounting mechanism (40) comprising a number of mounting brackets (42), each for exchangeably mounting one of the battery modules (26) to the aircraft (10). Each of the battery packs (24) can be a virtual battery pack (24), which is obtained by electrically connecting a predetermined number of the battery modules (26).