Removable Aircraft Battery Frame with Thermal Venting

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Solution Overview

Problem

Lithium chemistry batteries in aircraft propulsion systems face issues with thermal runaway due to cell failures, leading to dangerous and difficult-to-extinguish fires, which can cascade and destroy the aircraft, and existing technologies do not adequately address these risks.

Innovation Solution

A modular and structurally integrated battery system with a battery frame that provides support and includes temperature control mechanisms, venting systems, and a liquid or air heat transfer system to manage heat and prevent the spread of fires, allowing for safe removal and charging of batteries outside the aircraft.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If lithium chemistry batteries with increased energy density are used for aircraft propulsion, then the energy density and propulsion efficiency are improved, but the risk of thermal runaway and fire hazard increases

Engineering Contradiction:

Improveenergy densityVSAvoidfire hazard

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

The battery is divided into multiple separate battery modules that can be independently contained and removed. Each module is separated by spacing structures and fire-resistant barriers, preventing thermal runaway from cascading across the entire battery system. The modular design allows individual modules to be isolated and handled separately during charging and maintenance operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The battery modules are designed to be completely removable from the aircraft for charging outside the aircraft. This extraction of the battery from the aircraft structure eliminates the fire hazard from the aircraft during charging operations. The removable design allows the battery to be taken out of the pressurized, oxygen-rich aircraft environment and charged in a controlled external environment.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If a fixed battery system is integrated into the aircraft structure for structural support, then the structural integrity during flight is improved, but the ease of removal for charging deteriorates

Engineering Contradiction:

Improvestructural integrityVSAvoidease of removal

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The battery mounting system transitions from a fixed permanent installation to a dynamic removable design. Quick-connect mechanisms and releasable fasteners allow the battery modules to be easily installed and removed while maintaining structural integrity during flight. The system adapts between providing full structural support during operation and allowing rapid removal for charging.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The battery frame and mounting structure serve multiple functions: providing structural support to the aircraft during flight, enabling easy removal and installation for charging, and maintaining battery module positioning. The universal design integrates structural, mechanical, and operational requirements into a single multi-functional system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Volume of moving object

If battery modules are closely packed to maximize space utilization, then the volume efficiency is improved, but the heat management and fire containment capability deteriorate

Engineering Contradiction:

Improvespace utilizationVSAvoidheat management

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The battery module design incorporates local variations in spacing and thermal management resources. Modules with higher thermal loads have enhanced cooling provisions and greater spacing, while modules with lower thermal loads use minimal spacing. Fire barriers and thermal insulation are strategically placed at critical locations where heat generation is highest or where thermal runaway propagation risk is greatest.

Inventive Principle:

Principle #3Local quality

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 system ensures structural integrity during flight and crash conditions, effectively manages thermal runaway by containing and dissipating heat, reducing the risk of fire spread and enhancing safety during charging and operation.

Implementation Method 1

a liquid or air heat transfer system to manage heat and prevent the spread of fires

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

In thermal runaway, the damaged cell overheats, catches fire and produces toxic combustion gases

Methodology Applied

Scientific EffectThermal runaway: Combustion

Data Source

PatentUS11682917B1Apparatus, system and method for a removable aircraft battery

Publication Date: 2023.06.20 PIASECKI AIRCRAFT CORP

AI summary

A removable battery to provide motive power for an aircraft includes a battery frame and removable, interchangeable battery modules. Each of the battery modules defines module common space through which liquid heat transfer fluid flows during charging of the battery when the battery is removed from the aircraft and through which air as a heat transfer fluid flows during discharge of the battery, as during flight. The module common space also defines a combustion conduit to convey heated air and products of combustion safely outside the battery in the event of a cell fire during flight. The removable battery frame is a structural component of the aircraft.