Aircraft Battery Module Stacks With Parallel Plug-In Architecture
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Solution Overview
Problem
Existing battery systems for aircraft propulsion systems are limited by energy density, which restricts payload capacity and range due to the weight penalty associated with battery cells.
Innovation Solution
A modular battery system comprising an array of battery modules arranged in stacks, where each module is electrically coupled in parallel via positive and negative plug and receptacle connections, with optional battery management, venting, voltage regulation, and thermal conditioning, allowing for efficient swapping and configuration based on aircraft service and mission requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If battery systems are used to power aircraft propulsion systems, then electrical power for propulsion is provided, but weight penalty increases which limits payload capacity and range
Solution Approach 1:
The battery system is divided into multiple modular battery modules that can be independently configured and arranged in stacks. Each module contains a standardized number of battery cells organized in series strings, allowing the overall system to be segmented into manageable units that can be optimized for different weight and power requirements based on specific flight missions.
Solution Approach 2:
The patent enables parameter changes by allowing different numbers and configurations of battery modules to be assembled based on specific flight requirements. The modular design permits adjustment of total battery capacity, weight, and power output by adding or removing modules, thereby optimizing the weight-power ratio for different payload and range scenarios.
2Power
If battery modules are electrically coupled in parallel to provide power, then power delivery capability increases, but system complexity increases due to interconnections
Solution Approach 1:
The battery modules employ universal plug and receptacle interfaces that can be consistently applied across all modules regardless of their position in the stack. This standardized interface design allows any module to be electrically coupled to any other module through the same connection mechanism, simplifying the overall system architecture and reducing the complexity of interconnections while maintaining high power delivery capability through parallel coupling.
3Adaptability or versatility
If modular battery system is implemented for flexible configuration, then adaptability to different flight scenarios improves, but manufacturing and assembly complexity increases
Solution Approach 1:
The battery system is segmented into standardized modules that can be manufactured independently using uniform processes. Each module contains a standardized number of battery cells (e.g., six cells per module) arranged in identical series strings, which simplifies manufacturing by allowing mass production of identical units that can then be assembled in different configurations to meet various flight scenario requirements.
Solution Approach 2:
The modular design with standardized interfaces and uniform module specifications enables a single manufacturing process to produce all modules, which can then be universally assembled into different stack configurations. This universality reduces manufacturing complexity by eliminating the need for custom production lines for different battery configurations while maintaining high adaptability to various flight scenarios.
Data Source
AI summary
A modular battery system includes an array of battery modules arranged in at least one stack. Each battery module includes a plurality of battery cells, a first side having positive and negative receptacles and a second side, that is opposite of the first side, having positive and negative plugs. The receptacles and plugs are configured such that adjacent battery modules in a side-by-side relationship are electrically coupled together via plug and receptacle connections and such that the battery modules are electrically coupled together in parallel. An interconnection electrically couples each stack of battery modules together via plug and receptacle connections with one of the battery modules in each stack such that the stacks of battery modules are electrically coupled together in parallel. Each of the battery modules includes a voltage regulator configured to convert voltage between a battery cell voltage and a bus voltage.