Composite Panel Battery Integration Using Solid Electrolytes

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Solution Overview

Problem

Aircraft batteries face challenges due to the weight and safety concerns associated with traditional lithium-ion chemistries, particularly those using liquid electrolytes, which reduce energy density and require significant protective measures, and space and weight constraints in aircraft applications.

Innovation Solution

Integration of solid electrolyte batteries into composite panels, utilizing a solid electrolyte chemistry that is thermally stable and safer, allowing for reduced protective measures and enabling the batteries to serve as both structural and energy storage components, thereby optimizing weight and space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If lithium-ion batteries with liquid electrolyte are used in aircraft, then energy storage capacity is improved, but weight and safety risks increase due to required protective measures

Engineering Contradiction:

Improveenergy storage capacityVSAvoidbattery system weight

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The patent changes the electrolyte state from liquid to solid, fundamentally altering the physical parameters of the battery system. This parameter change eliminates the need for protective containment structures and cooling systems, directly reducing battery system weight while maintaining energy storage capacity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts and removes the liquid electrolyte component entirely, replacing it with solid electrolyte. This extraction eliminates the harmful liquid component that requires extensive protective measures, thereby reducing the overall weight of the battery system without compromising energy storage functionality

Inventive Principle:

Principle #2Taking out (Extraction)

2Use of energy by moving object

If lithium-ion batteries with liquid electrolyte are used in aircraft, then energy storage capacity is improved, but safety deteriorates due to thermal runaway risks

Engineering Contradiction:

Improveenergy storage capacityVSAvoidsafety

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent changes the electrolyte from liquid to solid state, which fundamentally alters the thermal and chemical properties of the battery system. Solid electrolytes do not support flame propagation and have superior thermal stability, eliminating thermal runaway risks while preserving energy storage capacity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the potential harm of electrolyte leakage and combustion into a benefit by using solid electrolyte that cannot leak or combust. The solid state transforms a previously harmful liquid into a safe, stable material that inherently prevents thermal runaway while maintaining energy storage function

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If traditional battery protective measures are implemented, then safety is improved, but device complexity and weight increase

Engineering Contradiction:

ImprovesafetyVSAvoidprotective structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and removes the need for complex protective structures by using solid electrolyte that inherently provides safety. The solid electrolyte eliminates requirements for leak-proof containment, thermal management systems, and flame suppression mechanisms, thereby reducing device complexity

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The solid electrolyte provides self-protection through its inherent physical properties - it cannot leak, does not support combustion, and maintains structural integrity under thermal stress. This self-service safety mechanism eliminates the need for additional protective systems and reduces overall device complexity

Inventive Principle:

Principle #25Self-service

4Reliability

If liquid electrolyte is used in lithium-ion batteries, then ionic conductivity is improved, but weight and safety concerns worsen

Engineering Contradiction:

Improveionic conductivityVSAvoidelectrolyte weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent changes the electrolyte from liquid to solid state, altering the physical parameters while maintaining ionic conductivity through different mechanisms. Solid electrolytes conduct ions through crystal lattice structures or amorphous pathways, achieving comparable conductivity without the weight and safety issues of liquid electrolytes

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20250349961A1Integrated battery in composite panels

Publication Date: 2025.11.13 TEXTRON INNOVATIONS INC

AI summary

An integrated battery includes a composite panel having one or more batteries disposed in an interior of the composite panel, and having a panel connector, wiring connecting each battery of the one or more batteries to the panel connector, one or more first cover layers disposed on a first side of the one or more batteries and at a first panel side of the composite panel, and one or more second cover layers disposed on a second side of the composite panel opposite the first panel side. The one or more first cover layers cover the wiring, and at least one of the one or more first cover layers or the one or more second cover layers covers the one or more batteries.