Cork-Lined Aircraft Battery Case for Thermal Runaway Containment
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Solution Overview
Problem
High voltage battery packs in aerospace applications are prone to thermal runaway due to excessive heating, which can lead to fire, damage to the aircraft structure, and risk of electric shock, and existing protective measures are inadequate for structural battery cases.
Innovation Solution
A battery case with a protective lining formed of cork and a phenolic binder provides enhanced thermal and mechanical protection, preventing the case from exceeding its glass transition temperature and containing thermal runaway events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If protective materials such as stainless steel, titanium, or intumescent materials are used, then thermal and flame protection is improved, but device complexity and mass increase
Solution Approach 1:
The patent applies composite materials by combining cork particles with a phenolic binder to create a protective lining that integrates thermal insulation, flame resistance, and structural support functions into a single composite system, reducing the need for multiple separate protective layers
Solution Approach 2:
The patent utilizes the glass transition temperature parameter of the phenolic binder to achieve a phase change that provides thermal protection. The binder transitions from a rigid state at low temperatures to a rubbery state at elevated temperatures, automatically providing thermal insulation without complex control systems
2Object-affected harmful factors
If thick protective lining is applied to cover all internal surfaces, then thermal insulation is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies local quality by selectively lining only specific internal surfaces of the battery case that require thermal protection, rather than uniformly covering all surfaces. This allows optimization of thermal insulation where most needed while reducing material usage and manufacturing complexity in less critical areas
Solution Approach 2:
The patent implements partial action by applying protective lining to only the necessary portions of the battery case interior, specifically the surfaces most exposed to thermal runaway risks, rather than providing complete全覆盖 protection, thereby balancing safety with manufacturing efficiency
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 cork and phenolic binder lining effectively absorbs thermal energy, insulates against flames and projectiles, and maintains structural integrity without significant mass addition, reducing the risk of fire and electric shock.
Implementation Method 1
The cork and phenolic binder lining effectively absorbs thermal energy
Implementation Method 2
insulates against flames and projectiles
Implementation Method 3
maintains structural integrity without significant mass addition, preventing the case from exceeding its glass transition temperature
Data Source
AI summary
A battery case for housing a battery and a method of fabricating such a battery case are provided. The battery case may be a battery case for an aircraft. The battery case comprises an enclosure having a cavity for housing the battery. An internal surface of the enclosure facing the cavity includes a protective lining comprising cork and a phenolic binder.