Annular Battery Cell Stack Cooling for Thermal Runaway Control

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Solution Overview

Problem

High-energy dense battery cells used in aircraft pose a fire hazard risk due to thermal runaway and have inherent failure modes, leading to high-weight systems that are undesirable in aerospace applications.

Innovation Solution

A battery cell system with an annular shape is designed to facilitate cooling, featuring a stack interface with annular housing, a cooling loop, and sensors connected to a battery management system (BMS) for thermal control and fire prevention, using heat dissipating FETs and a mechanical switch device for safe and efficient operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional battery systems are used to meet system voltage and energy requirements, then reliability and safety are improved, but weight increases significantly

Engineering Contradiction:

Improvereliability and safetyVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The battery system is divided into multiple modular battery cell stacks arranged in a circular configuration. Each stack contains multiple battery cells connected in series, and the modular design allows for scalable configuration to meet different voltage and energy requirements while maintaining a compact, lightweight structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The battery cells are arranged in a circular configuration with cooling channels positioned both radially (at the ends of the stacks) and axially (through the center of the circular arrangement). This three-dimensional cooling architecture improves thermal management efficiency without increasing system weight, allowing effective heat dissipation from all surfaces of the battery cells.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Use of energy by moving object

If high-energy dense battery cells are used, then energy requirements are met, but fire hazard risk due to thermal runaway increases

Engineering Contradiction:

Improveenergy densityVSAvoidfire hazard risk

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

A cooling fluid circulation system is implemented that proactively removes heat from battery cells before thermal runaway conditions can develop. Temperature sensors continuously monitor each cell, and the cooling system adjusts fluid flow rates to maintain temperatures below critical thresholds, preventing the conditions necessary for thermal runaway rather than merely responding after it begins.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

A cooling fluid acts as an intermediary substance between the battery cells and the external environment. The fluid circulates through channels positioned at the ends and center of the battery stacks, absorbing heat from the high-energy dense battery cells and transporting it away, thereby mediating the thermal interaction and preventing direct heat accumulation that could lead to fire hazards.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If traditional cooling arrangements are used, then thermal management is provided, but cooling efficiency is insufficient for high-energy dense batteries

Engineering Contradiction:

Improvethermal managementVSAvoidcooling efficiency

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

Cooling channels are positioned at specific locations including the radial ends and the axial center of the battery cell stacks. This localized cooling arrangement directs cooling fluid to areas of highest heat generation, maximizing cooling efficiency where it is most needed rather than using a uniform cooling approach across the entire battery system.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The cooling system utilizes both radial cooling channels at the ends of the battery stacks and axial cooling channels through the center of the circular arrangement. This multi-dimensional cooling architecture allows heat to be extracted from all surfaces of the battery cells simultaneously, dramatically improving overall cooling efficiency compared to single-direction cooling approaches.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 system provides improved thermal control, prevents and extinguishes thermal runaway, and reduces weight while maintaining reliability, making it suitable for volume and weight-sensitive applications like aircraft energy storage.

Implementation Method 1

A cooling loop is defined about the battery cell stack and the stack interface and through central through holes of the battery cell stack and the stack interface

Methodology Applied

Scientific EffectHeat transfer: Convection

Implementation Method 2

The stack interface can include a plurality of heat dissipating field effect transistors (FETs)

Methodology Applied

Scientific EffectHeat dissipation: Thermal Radiation

Data Source

PatentUS11804630B2Battery system with thermal control loop

Publication Date: 2023.10.31 HAMILTON SUNDSTRAND CORP

AI summary

A battery cell system includes a plurality of battery cells having an annular shape abutting one another to form a battery cell stack with an annular shape to facilitate cooling. The battery cell system includes a stack interface having an annular housing operatively connected to the plurality of battery cells. A cooling loop is defined about the battery cell stack and the stack interface and through central through holes of the battery cell stack and the stack interface.