Stacked Battery Modules With Sealed Envelopes for Overpressure Retention
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Solution Overview
Problem
Current battery packs for the aeronautical field face challenges in modularity, ease of assembly/disassembly, safety during thermal runaway, and the need for quick maintenance, particularly in environments where space and weight constraints are critical, with existing solutions failing to adequately manage gas overpressure and ensure mechanical retention while minimizing components for assembly risks.
Innovation Solution
A modular battery pack design featuring stacked modules with curved casing walls for improved pressure resistance, axial electrical connections, and integrated gas evacuation holes, using high-performance polymers for the casings and connectors that allow for easy reconfiguration and quick assembly/disassembly, along with a Battery Management System (BMS) for safety, and thermal insulation to manage heat flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional rigid metal packaging is used for battery modules, then mechanical strength and pressure resistance are improved, but weight increases and ease of assembly/disassembly deteriorates
Solution Approach 1:
The patent changes the material parameter from traditional metal to high-performance polymer, transforming the packaging material's properties to achieve both lightweight and sufficient strength requirements through material science advancement
Solution Approach 2:
The patent employs composite material structures in the polymer packaging, combining multiple polymer layers with different functions (structural support, thermal management, electrical insulation) to achieve comprehensive performance without using heavy metals
2Device complexity
If battery modules are stacked with direct electrical contact, then electrical connection is simplified, but safety deteriorates due to thermal runaway propagation risk
Solution Approach 1:
The patent segments the battery pack into independent modules, each with its own packaging that provides electrical insulation. This segmentation prevents thermal runaway propagation between modules while maintaining simplified electrical connections through standardized interfaces
Solution Approach 2:
The polymer packaging acts as an intermediary element between adjacent battery modules, providing electrical insulation and thermal barrier properties that prevent direct contact and potential thermal runaway propagation, while still allowing mechanical stacking
3Ease of manufacture
If flat casing walls are used for module packaging, then manufacturing is simplified, but pressure resistance during thermal runaway deteriorates
Solution Approach 1:
The patent applies curved surfaces to the casing walls, using arch-like or domed structures that naturally distribute and resist internal pressure during thermal runaway events, while maintaining manufacturability through standardized molding techniques
4Reliability
If multiple separate components are used for electrical connection, then connection reliability is improved, but assembly time and device complexity increase
Solution Approach 1:
The patent merges mechanical support and electrical connection functions into the integrated polymer packaging structure, which provides both structural integrity and built-in electrical insulation, eliminating the need for separate connection components and reducing assembly steps
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 enhances safety and ease of maintenance by allowing quick configuration changes, withstanding thermal runaway pressures, and reducing the risk of electrical disconnections and fires, while minimizing weight and component count, making it suitable for on-board applications in aircraft.
Implementation Method 1
the first electrical connector being mounted electrically through a longitudinal end wall of the casing which is of convex shape... in the event of overpressure generated during abnormal/accidental operation... limits the movement of the electrical connection point... prevents the risk of electrical disconnections
Implementation Method 2
thermal insulation to manage heat flow
Implementation Method 3
operate according to the principle of insertion or deinsertion, or in other words intercalation-deintercalation, of metal ions in at least one electrode
Implementation Method 4
separator impregnated with electrolyte between a positive electrode or cathode and a negative electrode or anode... generates the current
Data Source
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AI summary
The invention essentially consists of a modular battery pack made by stacking modules, preferably identical, each module housing several accumulators held in a support, the electrical connection between adjacent modules being made, preferably along the central axis, at each longitudinal end of the housings.