Modular Battery Stack Barriers for eVTOL Thermal Runaway Containment
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Solution Overview
Problem
Battery assemblies for electrical propulsion VTOL aircraft face challenges in containing thermal runaway events while maintaining mechanical and thermal integrity, as current solutions do not adequately prevent the spread of heat and mechanical failure within the battery stack, posing catastrophic risks during flight.
Innovation Solution
The battery assembly incorporates barrier plate members between neighboring battery cells, forming sealed modules within a housing, which act as both thermal and mechanical isolators, preventing the propagation of thermal runaway events and providing structural support, along with a cooling arrangement, electronics for real-time monitoring, and overpressure vents for controlled gas release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If high capacity battery assemblies are used to meet power requirements, then energy storage capability is improved, but the risk of catastrophic thermal runaway events increases
Solution Approach 1:
The battery assembly is divided into multiple sealed modules, each containing a specific number of battery cells (e.g., six battery cells per module). Barrier plate members are inserted between neighboring battery cells to create physical separation. This segmentation ensures that thermal runaway events are confined to individual modules or small groups of cells rather than propagating through the entire high-capacity battery assembly, thus maintaining reliability while preserving energy storage capability.
2Reliability
If thermal isolation measures are implemented to contain thermal runaway events, then safety is improved, but heat conduction from inside to surroundings increases
Solution Approach 1:
The battery assembly is segmented into multiple sealed modules with barrier plate members that provide thermal isolation between cells. This containment strategy directs heat away from surrounding components and confines thermal energy within isolated modules, actually reducing harmful heat conduction to the aircraft structure while improving safety.
Solution Approach 2:
The barrier plate members act as intermediary thermal barriers between battery cells. These plates are positioned to intercept and block heat transfer pathways, serving as mediators that prevent thermal runaway propagation while managing heat flow in a controlled manner that protects surrounding components.
3Reliability
If barrier plate members are inserted between battery cells to contain thermal runaway, then thermal isolation is improved, but mechanical stiffness and rigidity deteriorate
Solution Approach 1:
The barrier plate members are designed to perform multiple functions simultaneously: they provide thermal isolation between battery cells to prevent thermal runaway propagation, and they serve as structural stiffeners that enhance the mechanical rigidity of the battery assembly. This multi-functionality resolves the contradiction by making the same component beneficial for both thermal and mechanical performance.
Solution Approach 2:
The barrier plate members are constructed from composite materials that combine thermal insulation properties with mechanical strength. These composite structures provide both thermal isolation and structural support, eliminating the trade-off between thermal protection and mechanical stiffness.
4Stability of the object's composition
If battery cells are individually wired and managed to meet mechanical requirements, then mechanical properties are improved, but device complexity increases
Solution Approach 1:
The battery assembly is segmented into modular sealed units, each containing a defined number of battery cells with standardized wiring and management. This modular segmentation simplifies the overall complexity by creating repeatable, pre-assembled units that can be systematically integrated, reducing the burden of individual cell management while maintaining mechanical stability.
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
This design effectively contains thermal runaway events within isolated modules, maintains mechanical integrity, and enhances safety and reliability by preventing heat and mechanical failure propagation, ensuring safe operation and reduced risk of catastrophic failures during flight.
Implementation Method 1
the barrier plate members not only lead to a thermal isolation of potential thermal runaway events but rather also to a mechanical isolation thereof
Implementation Method 2
by fixing them to the housing of the battery stack assembly, they also contribute to the mechanical stiffness and rigidity of the overall battery assembly
Data Source
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AI summary
The present invention relates to a battery assembly (42), in particular for use in an electrical propulsion VTOL aircraft, comprising a base plate assembly (44), at least one battery stack assembly (20), each comprising a plurality of battery cells (12) stacked on top of the base plate assembly (20) along a stacking direction (S) thus forming a battery cell stack (10) and electrically connected in parallel or in series, and a housing (22) surrounding the battery cells (12) on all four sides, wherein each battery stack assembly (20) comprises at least one barrier plate member (16) inserted between neighboring battery cells (12) and connected to the housing (22) in order to form at least two separate sealed modules (14) of battery cells (12) within the corresponding battery stack assembly (20).