eVTOL Battery Assembly With Segregated Electronics and Gas Venting

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Solution Overview

Problem

Battery assemblies used in electric vehicles are not suitable for electrical propulsion aircraft due to different load paths and safety regulations, and there is a need for optimal load distribution and protection from thermal runaway in aircraft applications.

Innovation Solution

A battery assembly comprising a battery box with a housing, a base plate, and an electronics unit, where the battery cells are stacked on the base plate, and the two units are interfaced via interface units for independent operation and maintenance, with features like cooling channels, burst disks, and physical segregation to prevent thermal runaway and enhance safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If battery cells are stacked vertically on the base plate, then load distribution during hard landing is improved, but device complexity increases due to additional housing and mounting structures

Engineering Contradiction:

Improveprotection from thermal runawayVSAvoidhousing structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The battery assembly is divided into separate modules: battery cells, base plate, housing, and electronics unit. This segmentation allows each component to be optimized independently for its specific function while simplifying the overall structure and assembly process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electronics unit is extracted and mounted separately on the housing rather than being integrated with the battery cells. This separation protects sensitive electronic components from thermal runaway and mechanical stress while simplifying the battery cell structure.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If battery cells are physically segregated and stacked vertically, then protection from thermal runaway is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal runaway protectionVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple functional elements are combined into integrated components: the base plate integrates mounting structures and electrical connections, the housing combines protection and structural support, and the interface unit merges electrical and mechanical coupling functions.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If battery box and electronics unit are physically separated, then safety against thermal runaway is improved, but device complexity increases due to interface requirements

Engineering Contradiction:

Improvesafety of electronic componentsVSAvoidinterface unit complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The interface unit combines multiple functions into a single integrated component: electrical connections, mechanical mounting, and thermal management interfaces are merged into one unit that couples the battery box and electronics unit, reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The interface unit acts as an intermediary between the battery box and electronics unit, providing a standardized coupling mechanism that simplifies connections while maintaining safety isolation. This mediator enables independent replacement of either component.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If battery cells are arranged in vertical stacks, then load distribution during hard landing is improved, but volume allocation efficiency decreases

Engineering Contradiction:

Improveload distributionVSAvoidspace utilization

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The battery assembly uses a modular design with the base plate providing structural support and load distribution while allowing flexible arrangement of battery cell stacks. This dynamic configuration optimizes both load bearing and space utilization based on specific application requirements.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20230387528A1Battery assembly, in particular for use in an electrical propulsion VTOL aircraft, and electrical propulsion VTOL aircraft comprising such a battery assembly

Publication Date: 2023.11.30 LILIUM EAIRCRAFT GMBH

AI summary

Disclosed is a battery assembly, comprising a battery box, comprising a housing including a base plate and a cover; at least one battery cell stack mounted inside the housing, wherein each battery cell stack comprises a plurality of battery cells stacked on top of the base plate along a stacking direction and electrically connected in series or in parallel; electrical connectors disposed on the outer side of the housing; and an interface unit for coupling with an electronics unit; and an electronics unit, comprising electronic control components; and an interface unit for coupling with the battery box; wherein in use the battery box and the electronics unit are interfaced by their such respective interface units such that operation of the at least one battery cell stack is controlled by the electronic control components of the electronics unit. Furthermore, the invention relates to an electrical propulsion VTOL aircraft comprising such a battery assembly.