CMC Battery Enclosure for Lightweight Fire Containment
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Solution Overview
Problem
Existing enclosures for electrochemical power units, particularly in the aerospace industry, are either heavy due to metal construction or prone to failure during thermal events when using organic composites, lacking adequate thermal insulation and structural integrity.
Innovation Solution
The enclosure is made with a ceramic matrix composite (CMC) that includes a ceramic coating, providing thermal insulation and structural support, capable of withstanding high temperatures and protecting against thermal events while maintaining a lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal enclosures are used, then structural strength and fire protection are improved, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining CMC (ceramic matrix composite) with a ceramic coating to create an enclosure that achieves both lightweight properties and high structural strength. The CMC provides the base structural framework while the ceramic coating enhances surface durability and thermal resistance, together resolving the contradiction between weight reduction and strength maintenance.
2Weight of moving object
If organic composites are used, then weight is reduced, but thermal insulation and structural integrity deteriorate during thermal events
Solution Approach 1:
The patent applies parameter changes by selecting CMC as the base material, which fundamentally changes the thermal and mechanical parameters compared to organic composites. The ceramic coating further modifies surface properties to resist thermal degradation. This material parameter transformation enables the enclosure to maintain both lightweight characteristics and high reliability during thermal events.
3Weight of moving object
If CMC is used without ceramic coating, then weight is reduced and manufacturing is simplified, but resistance to oxidative degradation and hot corrosive gases deteriorates
Solution Approach 1:
The ceramic coating serves as an intermediary protective layer between the CMC and the harsh thermal environment. It mediates the interaction by providing a barrier against oxidative degradation and hot corrosive gases, allowing the CMC to maintain its lightweight advantages while gaining enhanced chemical and thermal resistance through the coating's protective function.
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 CMC and ceramic coating combination offers effective thermal and structural protection, preventing the spread of fire and debris, ensuring the safety of aircraft components and occupants, while reducing weight and maintaining operational integrity during high G loadings and crash landings.
Implementation Method 1
The ceramic coating is supported by the CMC and acts to protect the ceramic coating and CMC from high temperature oxidative degradation, in the event of a thermal event.
Implementation Method 2
the CMC is positioned such that it is exposed to the extremely high temperatures of a thermal event, and acts to lower these temperatures to more manageable temperatures for insulating the components distal the CMC
Data Source
AI summary
An enclosure is provided which defines an internal volume for housing an electrochemical power unit, wherein at least a region of the enclosure is formed of a material comprising a ceramic matrix composite (CMC). The enclosure disclosed herein may be thought of as a “structural insulation system”.