Battery Stack Interface FET Layout 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 a stack interface featuring annular metallic conductors, heat dissipating field effect transistors, and a battery management system that includes a motor drive assembly for circulating a heat transfer fluid, along with sensors for monitoring and controlling thermal stability, to prevent and extinguish thermal runaway while reducing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If high-energy dense battery cells are used to meet system voltage and energy requirements, then energy density is improved, but fire hazard risk and thermal runaway risk increase

Engineering Contradiction:

Improveenergy densityVSAvoidfire hazard risk

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

A heat transfer fluid is introduced as an intermediary substance between the battery cells and the environment. The fluid circulates through channels in the stack interface, absorbing heat from the battery cells and preventing thermal runaway. This intermediary medium enables high-energy dense cells to operate safely by mediating heat transfer and preventing direct thermal contact between cells.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces passive mechanical thermal isolation with an active fluid-based thermal management system. Instead of relying on physical barriers alone, the system uses circulating heat transfer fluid to dynamically control heat transfer, allowing high-energy dense cells to be packed closely while maintaining safety through active thermal regulation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If hundreds of battery cells are used to meet system voltage and energy requirements, then energy capacity is improved, but system weight increases

Engineering Contradiction:

Improveenergy capacityVSAvoidsystem weight

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

Multiple battery cells are merged into compact stacks with shared thermal management infrastructure. The stack interface integrates heat dissipation FETs and fluid channels that serve multiple cells simultaneously, reducing redundant components and overall system weight while maintaining the energy capacity of hundreds of cells.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stack interface structure serves multiple functions: it provides electrical connections between cells, dissipates heat from multiple cells through integrated FETs, and guides heat transfer fluid circulation. This multi-functional design eliminates the need for separate thermal management components for each cell, reducing system weight.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If conventional battery systems are used, then reliability is improved through numerous cells, but weight increases making the system undesirable for aerospace applications

Engineering Contradiction:

Improvesystem reliabilityVSAvoidsystem weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The battery system is segmented into modular stacks, each with its own integrated thermal management interface. This segmentation allows for compact packaging with shared resources while maintaining the reliability of multiple cells. The modular design reduces overall system weight compared to conventional distributed thermal management systems.

Inventive Principle:

Principle #1Segmentation

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 thermal runaway, and reduces weight, resulting in a safer and more reliable battery system for aircraft applications.

Implementation Method 1

a plurality of heat dissipating field effect transistors (FETs) arranged more proximate to the outer perimeter than the center

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

a motor drive assembly positioned within an inner diameter hole of the annular housing configured and adapted to drive circulation of a heat transfer fluid around the plurality of stacks

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentEP3975310B1Battery cell system with field effect transistors

Publication Date: 2024.12.25 HAMILTON SUNDSTRAND CORP

Figure 1A~1B
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Figure 3

AI summary

A battery cell system (100) includes a plurality of battery cells (104) abutting one another to form a battery cell stack (102). The battery cell system includes a stack interface (114) operatively connected to the battery cells. The stack interface includes a housing (131) defining a center and an outer perimeter (122). The stack interface includes a plurality of heat dissipating field effect transistors, FETs (118) arranged more proximate to the outer perimeter than the center.