Battery Pack Core Structure for Thermal Runaway Pressure Containment
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Solution Overview
Problem
Aerospace batteries face risks of uncontrolled fires and explosions due to flammable components and thermal runaway, which can lead to damage and safety hazards within the battery housing.
Innovation Solution
The battery housing is designed with an elliptical cylinder shape and a specific weld location to withstand high pressures, combined with a cold plate and silicone bushings to manage heat and vibrations, and filled with ceramic felt and closed cell foam to reduce combustion risks and contain thermal events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the battery housing uses a conventional cylindrical shape with standard welding, then the manufacturing process is simple, but the housing cannot withstand high pressures during thermal runaway events
Solution Approach 1:
The patent applies an elliptical cylinder shape to the battery housing instead of a conventional cylindrical shape. This curved geometry distributes stress more evenly during pressurization events, significantly improving pressure resistance while maintaining a relatively simple manufacturing process using standard sheet metal forming and welding techniques.
2Strength
If the weld location is positioned at the high-stress area for easier manufacturing, then the welding process is simpler, but the housing fails under pressure during thermal events
Solution Approach 1:
The patent positions the weld location specifically at the low-stress perimeter area of the elliptical cylinder, creating a non-uniform stress distribution that protects the weld joint from high stresses during pressurization. This localized quality enhancement ensures the weld remains intact during thermal runaway events while maintaining manufacturing feasibility.
3Temperature
If flammable components are used in the battery, then the battery can operate at higher temperatures, but uncontrolled fires and explosions occur during thermal runaway
Solution Approach 1:
The patent introduces a fire suppression system that utilizes the thermal energy and pressure build-up during thermal runaway events to activate suppression mechanisms. The harmful thermal runaway process itself triggers the release of fire suppressant materials, converting the dangerous event into an automated safety response that prevents uncontrolled fires and explosions.
Solution Approach 2:
The patent employs fire suppressant materials as intermediary substances between the battery cells and the external environment. These materials are positioned to intervene in the thermal runaway process, suppressing flame propagation and preventing explosion while allowing the battery to operate at elevated temperatures during normal operation.
4Reliability
If thermal management components are added to manage heat and vibrations, then the safety during thermal events is improved, but the device complexity increases
Solution Approach 1:
The patent designs the housing structure to serve multiple functions simultaneously: it provides mechanical support, acts as a thermal barrier, contains pressure during thermal runaway, and guides the fire suppressant release. This multi-functionality reduces the need for separate dedicated components, thereby limiting the increase in device complexity while maintaining improved safety.
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 enhances the pressure resistance and thermal management of the battery housing, reducing the risk of uncontrolled fires and explosions, and maintaining structural integrity during thermal events.
Implementation Method 1
a cold plate comprising a plurality of cooling channels
Implementation Method 2
a plurality of silicone bushings, a silicone bushing surrounding each battery cell of the plurality of battery cells
Implementation Method 3
a closed cell foam filling open space between the battery pack core, the ceramic felt, and the housing
Implementation Method 4
a ceramic felt surrounding at least part of the battery pack core
Data Source
AI summary
A battery pack core may include a cold plate comprising a plurality of apertures defined between a first major surface and a second major surface of the cold plate; a plurality of battery cells, a single battery cell positioned in each aperture of the plurality of apertures such that a first end of the battery cell projects beyond the first major surface and a second end of the battery cell projects beyond the second major surface; and a plurality of silicone bushings, a silicone bushing surrounding each battery cell of the plurality of battery cells and contacting a wall of the aperture in which the battery cell is positioned.