Exothermic Composite Battery Structure for Rapid Low-Temperature Heating
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Solution Overview
Problem
Munitions face challenges in maintaining operational readiness at extremely low temperatures, as existing heating methods are inefficient, occupy valuable space, and cannot be activated quickly enough for rapid deployment, especially in gun-fired systems where external power sources are not available.
Innovation Solution
Exothermic-based composite structures that are load-bearing and capable of adaptive heating on-demand, using exothermic materials and phase change members to generate heat rapidly and efficiently, eliminating the need for additional support structures and minimizing volume, while providing thermal insulation to maintain component functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrical heating components with wiring and support structures are used to heat munition components at low temperatures, then heating capability is provided, but valuable munition volume is occupied and device complexity increases
Solution Approach 1:
The patent combines the heating function with the structural support function into a single integrated component. The exothermic heating elements are embedded within the structural matrix of the munition, eliminating the need for separate heating components, wiring, and support structures. This merging of functions provides heating capability while minimizing volume occupation.
Solution Approach 2:
The structural matrix material serves multiple functions: it provides mechanical support, contains the exothermic heating elements, and facilitates heat distribution. This multi-functional design eliminates the need for dedicated heating components and their associated support structures, thereby preserving valuable munition volume.
2Temperature
If electrical heating components are used to heat munition components at low temperatures, then heating capability is provided, but device complexity increases due to wiring and support structures
Solution Approach 1:
The heating function is merged with the structural matrix, eliminating the need for separate wiring harnesses, control circuits, and support structures. The exothermic materials are directly embedded in the matrix, creating a simplified integrated system that reduces device complexity while maintaining heating capability.
Solution Approach 2:
The exothermic heating system is self-contained and self-activating. The chemical reaction of the exothermic materials generates heat autonomously without requiring external electrical power sources, control wiring, or complex thermal management systems, thereby significantly reducing device complexity.
3Temperature
If conventional heating methods are used in gun-fired munitions, then heating can be provided, but response time is too slow for rapid deployment
Solution Approach 1:
The patent changes the heating mechanism from electrical resistance heating to exothermic chemical reaction. This parameter change enables much faster heat generation and delivery, achieving the required temperature rise in seconds rather than minutes, thus meeting the rapid response requirements of gun-fired munitions.
Solution Approach 2:
The exothermic heating materials are pre-positioned and pre-configured within the structural matrix before munition deployment. Upon activation, the chemical reaction immediately begins generating heat without requiring setup or external power connection, enabling instantaneous response for rapid deployment scenarios.
4Speed
If exothermic materials are used as heating source, then fast response and high heat generating capacity are achieved, but structural strength to withstand launch accelerations and spin rates must be ensured
Solution Approach 1:
The exothermic heating elements are embedded within a load-bearing structural matrix that is designed to withstand launch accelerations of up to 75,000 Gs and spin rates of up to 200 Hz. The matrix structure provides mechanical strength while containing the heating materials, integrating structural and thermal functions into a single robust system.
Solution Approach 2:
The patent employs composite material construction where exothermic materials are integrated within a strong structural matrix. This composite structure combines the high heat generating capacity of exothermic materials with the mechanical strength required to withstand extreme launch and flight conditions, achieving both fast response and structural integrity.
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
Significantly extends the run-time and high-pulsed power of reserve power systems, enhances the stand-off range, and improves safety by ensuring operational readiness at low temperatures without sacrificing lethality or increasing volume, effectively managing thermal challenges in munitions.
Implementation Method 1
exothermic materials are used as a heating source due to their high heat generating capacity and very fast response even at temperatures as low as −55 degrees C
Implementation Method 2
phase change members in its structure to efficiently store heat energy that is generated by high temperature burning of pyrotechnics materials to provide a relatively uniform heating source at a predictable temperature
Implementation Method 3
after exhausting their heating sources, would function as effective thermal insulation to keep the components warm at low temperatures
Data Source
AI summary
A thermal battery including: a battery core; and a load-bearing structure at least partially surrounding the battery core. The load-bearing structure including: a plurality of tubes arranged adjacent to one another and connected to at least one adjacent tube of the plurality of tubes; and an exothermic material disposed in the plurality of tubes. The load-bearing structure can include one or more initiation devices for initiating the exothermic material. The plurality of tubes can be compressed in a cross-section to compact the exothermic material disposed on the plurality of tubes. A thermal isolation material can also be disposed at one or more ends of the plurality of tubes.