Wing Battery Assembly Layout to Decouple Aircraft Structural Loads
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Solution Overview
Problem
The integration of batteries into the wings of electric aircraft poses challenges such as increased aerofoil thickness, sub-optimal structural elements, ice protection requirements, and design complexities, which affect aerodynamic efficiency and operational properties.
Innovation Solution
A battery assembly is configured to be mounted within the wing with a free side, decoupling it from structural loads, allowing multiple modules to be arranged independently and reducing interference with the wing's load path, and incorporating a thermomechanical cover and thermal management system for safety and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If batteries are installed within the wing to provide adequate energy capacity, then energy storage capability is improved, but the wing occupies more space and may require increased aerofoil thickness which deteriorates aerodynamic efficiency
Solution Approach 1:
The wing is divided into multiple compartments separated by bulkheads, with batteries arranged in modular units within these compartments. This segmentation allows efficient space utilization without requiring increased overall wing thickness, maintaining aerodynamic efficiency while accommodating adequate battery volume.
Solution Approach 2:
Instead of arranging batteries only in the thickness direction (chordwise), the invention utilizes the spanwise direction and chordwise direction within the wingbox cross-section. This multi-dimensional arrangement maximizes battery capacity within the existing wing geometry without increasing aerofoil thickness.
2Ease of manufacture
If main structural elements (spars and ribs) are positioned to accommodate specific battery sizes, then battery installation is facilitated, but structural optimality for load-bearing is compromised
Solution Approach 1:
The wing structure is segmented into load-bearing components (spars and ribs) and non-load-bearing compartments (formed by bulkheads). This allows structural elements to be optimized for strength while batteries are accommodated in the segmented compartments without compromising structural integrity.
Solution Approach 2:
Bulkheads serve as intermediary structures between the load-bearing spars/ribs and the battery modules. These bulkheads facilitate easy battery installation and removal while being decoupled from the primary load path, allowing structural elements to maintain their optimal positions for strength.
3Reliability
If ice protection provisions are enlarged to sufficiently de/anti-ice the wing in icing conditions, then ice protection capability is improved, but available space for batteries in the central part of the wing is reduced
Solution Approach 1:
The wing is divided into a central compartment and tip compartments by bulkheads. Ice protection provisions are concentrated in the central compartment where they are most effective, while battery modules are arranged in the tip compartments. This segmentation allows both adequate ice protection and sufficient battery volume without direct spatial conflict.
Solution Approach 2:
Batteries are arranged primarily in the spanwise direction within the tip compartments rather than competing for chordwise space with ice protection systems. This dimensional arrangement allows both systems to coexist with adequate sizing for各自的 functions.
4Productivity
If flight controls and high-lift devices on the wing trailing edge are sized appropriately, then aerodynamic performance is improved, but available wingbox space for batteries is reduced
Solution Approach 1:
The wingbox is segmented into a central region (for flight controls and high-lift devices) and tip regions (for batteries). This segmentation allows aerodynamic components to occupy the central wingbox space where they are most effective, while batteries are positioned in the tip regions with adequate volume.
Solution Approach 2:
Batteries are arranged in the spanwise direction within the tip compartments rather than competing for the chordwise space needed by flight controls. This utilizes the full three-dimensional volume of the wingbox efficiently, accommodating both aerodynamic components and batteries without direct spatial conflict.
5Adaptability or versatility
If batteries are mounted within the wing, then energy storage is integrated, but batteries are exposed to bending and twisting loads which deteriorates reliability
Solution Approach 1:
Bulkheads serve as intermediary structures that decouple batteries from the primary load path. The batteries are mounted on these non-load-bearing bulkheads rather than directly on the load-bearing spars and ribs, isolating them from bending and twisting loads while maintaining integrated energy storage within the wing structure.
Solution Approach 2:
The battery mounting function is extracted from the load-bearing structural elements (spars and ribs) and placed on separate non-load-bearing bulkheads. This separation removes batteries from the stress field of wing bending and twisting, protecting them from load-induced damage while maintaining structural integration.
Data Source
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AI summary
The present disclosure relates to a battery assembly (300) configured to be mounted within at least one wing (200) of at least one aircraft (100). The battery assembly (300) includes at least one battery module (302) which includes at least one battery cell (460). The battery assembly (300) further includes at least one mounting structure (400) configured to mount the battery module (302), along a mounting side (402) of the battery module (302), to at least one support structure (207) within the wing (200). The battery assembly (300) is free of a mounting structure for mounting the battery module (302) along a second side (403) of the battery module (302), the second side (403) being substantially opposite from the mounting side (402). The present disclosure further relates to wing (200) of an aircraft (100), an aircraft (100), and method for installing a battery assembly (300).