Electric Aircraft Battery Module Casing for Thermal Runaway Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Electric aircraft batteries face challenges with thermal runaway, where overheating can lead to uncontrolled feedback loops and conflagration, potentially spreading to neighboring cells, due to uncontained ejecta and heat transfer.

Innovation Solution

A battery module casing with a lithiophobic surface containing an ejecta barrier and a non-lithiophobic surface for venting, designed to contain and isolate molten materials, electrolyte vapors, and off-gas from one battery cell to prevent them from influencing neighboring cells, thereby preventing the progression of thermal runaway.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If battery cells are placed in a battery module, then energy storage capacity is improved, but thermal runaway can spread to neighboring cells causing conflagration

Engineering Contradiction:

Improveenergy storage capacityVSAvoidthermal safety

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

The battery module is divided into individual cell compartments that physically separate battery cells. Each compartment acts as an independent containment zone that prevents thermal runaway from spreading between cells, while still allowing multiple cells to be packed together for high energy storage capacity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Thermal barriers and ejecta shields are introduced as intermediary components between adjacent battery cells. These barriers intercept hot ejecta and heat transfer paths, preventing thermal runaway propagation while maintaining the compact arrangement of cells for energy density.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If thermal barriers are added between battery cells, then thermal runaway propagation is prevented, but device complexity increases

Engineering Contradiction:

Improvethermal safetyVSAvoidmodule structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The cell compartment structure serves multiple functions simultaneously: it provides mechanical support for battery cells, enables thermal management through integrated cooling channels, and prevents thermal runaway propagation through built-in thermal barriers. This multi-functionality reduces overall device complexity despite the added safety features.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Thermal barriers and ejecta shields are nested within the existing cell compartment structure rather than being added as separate external components. The thermal management channels are integrated into the compartment walls, creating a compact nested arrangement that minimizes overall module complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Volume of moving object

If battery cells are closely packed for energy density, then volume efficiency is improved, but heat transfer between cells increases thermal runaway risk

Engineering Contradiction:

Improvevolume efficiencyVSAvoidheat transfer

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The cell compartments use different material properties in different regions: thermally conductive materials are used in areas requiring heat dissipation, while thermally insulating materials with lithiophobic surfaces are used in areas where ejecta containment and thermal isolation are critical. This localized material selection optimizes both heat management and thermal runaway prevention.

Inventive Principle:

Principle #3Local quality

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 shields and isolates ejecta from neighboring battery cells, preventing heat and combustible materials from igniting and causing further thermal runaway, enhancing safety and reliability of electric aircraft batteries.

Implementation Method 1

the battery module casing includes: at least a lithiophobic surface including an ejecta barrier

Methodology Applied

Scientific EffectLithiophobic surface: Hydrophobe

Implementation Method 2

at least a non-lithiophobic surface configured to vent the cell ejecta

Methodology Applied

Scientific EffectVenting:

Data Source

PatentUS11848458B1Battery module configured for use in an electric aircraft

Publication Date: 2023.12.19 CUBERG INC

AI summary

A system including a battery module configured for use in an electric aircraft includes at least a battery cell and a battery module casing. The at least a battery cell includes at least a pair of cell tabs and at least a conductor. The battery module casing includes at least a lithiophobic surface with an ejecta barrier and at least a nonlithiphobic surface that is configured to vent the cell ejecta. The battery module casing closely matches the dimensions of the battery cell.