eVTOL Battery Assembly Layout for Thermal Runaway Containment
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Solution Overview
Problem
Battery assemblies used in electric vehicles are not suitable for electrical propulsion aircraft due to differing load paths and safety regulations, and there is a need for enhanced protection against thermal runaway, which is critical in aircraft applications where safe landing is not feasible.
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 provide efficient load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If battery assemblies from electric vehicles are used in aircraft, then power supply capability is achieved, but safety protection against thermal runaway is insufficient
Solution Approach 1:
The battery assembly is divided into multiple battery modules, each containing individual battery cells separated by partition walls. This segmentation isolates thermal runaway events to specific modules, preventing propagation to other cells. The electronics unit is also physically separated from the battery cells within the housing, creating additional safety zones that protect sensitive electronics from thermal events.
Solution Approach 2:
Partition walls act as intermediary barriers between battery cells, providing thermal and physical isolation. The housing structure serves as an intermediary protective layer between the battery cells and the electronics unit, preventing direct thermal contact while allowing electrical and data communication through interface units.
2Strength
If battery cells are stacked vertically on the base plate, then load distribution is optimized for aircraft landing impacts, but structural complexity increases
Solution Approach 1:
The battery cells are pre-stacked in vertical columns on the base plate before final assembly, creating a structured arrangement that optimizes load distribution. This preliminary stacking configuration ensures that impact forces from vertical landings are distributed across multiple cells and the base plate structure, rather than concentrating on individual cells.
Solution Approach 2:
The battery cells are arranged in a three-dimensional stacked configuration rather than a flat horizontal layout. This vertical stacking utilizes the height dimension of the housing, allowing optimized load-bearing characteristics for vertical impacts while maintaining a compact footprint. The modular stack design simplifies the overall structure compared to attempting to reinforce individual cells against impact.
Data Source
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AI summary
The present invention relates to a battery assembly (10), comprising a battery box (100), comprising a housing (100a) including a base plate (102) and a cover (104); at least one battery cell stack mounted inside the housing (100a), wherein each of the battery cell stacks in turn comprises a plurality of battery cells stacked on top of the base plate (102) along a stacking direction and electrically connected in series or in parallel; electrical connectors (108) disposed on the outer side of the housing (100a); and an interface unit for coupling with an electronics unit (200); and an electronics unit (200), comprising electronic control components (204); and an interface unit for coupling with the battery box (100); wherein in use the battery box (100) and the electronics unit (200) 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 (204) of the electronics unit (200). Furthermore, the invention relates to an electrical propulsion VTOL aircraft comprising such a battery assembly.