Modular Battery Cell Enclosure with Valve for Thermal Safety
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Solution Overview
Problem
Current aircraft battery systems are heavy, inefficient, and lack flexibility, as they often require replacing entire battery units due to a single defective cell, leading to weight and maintenance issues, and pose safety risks due to thermal runaway and overheating.
Innovation Solution
A modular battery system with individually housed lithium-ion cells and a distributed control system that monitors each cell's health and conditions, allowing for selective replacement and isolation of thermal issues, using a titanium housing and a carbon fiber end cap with a valve for fluidic access and a flame-retardant additive for safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fixed-size battery units are used in aircraft, then safety containment is improved, but aircraft weight increases and electrical capacity becomes inefficient
Solution Approach 1:
The battery system is divided into individual cell containers, each housing a separate energy storage cell with its own containment structure. This segmentation allows each cell to be independently contained for safety while the overall battery assembly can be optimized for weight and capacity requirements.
2Reliability
If traditional fixed-size battery units are used in aircraft, then safety containment is improved, but electrical capacity efficiency deteriorates
Solution Approach 1:
The battery system is divided into individual cell containers, each housing a separate energy storage cell with its own containment structure. This segmentation allows each cell to be independently contained for safety while the overall battery assembly can be optimized for weight and capacity requirements.
Solution Approach 2:
The battery system employs a modular architecture where individual cell containers can be dynamically configured and replaced based on capacity requirements and operational needs, allowing the electrical capacity to be efficiently matched to the aircraft's power demands.
3Reliability
If entire battery units are replaced due to a single defective cell, then system reliability is maintained, but weight and maintenance efficiency deteriorate
Solution Approach 1:
The battery system is divided into individual cell containers, each housing a separate energy storage cell with its own containment structure. This segmentation allows each cell to be independently contained for safety while the overall battery assembly can be optimized for weight and capacity requirements.
Solution Approach 2:
The defective energy storage cell is extracted from its container, which remains intact. This allows the problematic cell to be removed and replaced without affecting the other cells or the containment structure, significantly improving maintenance efficiency.
4Ease of repair
If modular cell containers are used, then maintenance efficiency is improved, but device complexity increases
Solution Approach 1:
The battery system is divided into individual cell containers, each housing a separate energy storage cell with its own containment structure. This segmentation allows each cell to be independently contained for safety while the overall battery assembly can be optimized for weight and capacity requirements.
Solution Approach 2:
Multiple functional elements (energy storage cell, containment structure, terminals, sensors, and control systems) are merged into integrated modular cell containers. This consolidation simplifies the overall system architecture while maintaining maintenance efficiency through standardized replaceable units.
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 modular design reduces weight, enhances safety by preventing thermal runaway, and allows for rapid maintenance by replacing only defective cells, resulting in significant weight savings and improved fuel efficiency.
Implementation Method 1
a valve positioned within the conduit and controlling fluidic flow through the conduit
Implementation Method 2
a flame-retardant additive for safety
Data Source
AI summary
Battery systems and associated methods are described herein. A representative battery system includes: a plurality of individual battery units that each include a battery cell enclosed in a housing with a sensor therein configured to sense a physical characteristic of the battery cell; and a controller configured to connect/disconnect each battery cell according to its physical status to/from a device/system monitoring the battery system, such as an overarching vehicle control system. A battery system may comprising an energy storage cell; a cell container surrounding the energy storage cell and comprising at least one power output terminal and a test port; an external housing defining an enclosure configured to encompass the cell container; a conduit attached to the test port of the cell container and accessible through the external housing; and a valve positioned within the conduit and controlling fluidic flow through the conduit.