Systems and methods for improved battery assemblies for EVTOL aircraft
This disclosure relates generally to high voltage power supply (HVPS) systems and battery assemblies for aircraft that use electrical propulsion systems. In one embodiment, an apparatus for safely venting battery cells in thermal runaway is provided. The apparatus includes: a mechanical support layer, the mechanical support layer configured to be attached to a battery assembly; and a vent flap layer attached to the mechanical support layer, the vent flap layer including vent flaps corresponding to battery cells in the battery assembly. Each vent flap includes one or more portions configured to deform to permit flow of gas from the battery cell corresponding to the vent flap.
1 . An apparatus for electrically connecting battery cells in a battery pack, comprising:
a plurality of battery cells, each battery cell including a positive and a negative terminal, the battery cells arranged adjacent to each other to form a plurality of battery cell rows, the plurality of battery cell rows further arranged adjacent to each other to form a battery column;
a current collector, comprising:
a plurality of positive electrical contacts, each positive electrical contact configured to electrically couple to a positive terminal of one of the battery cells;
a plurality of negative electrical contacts, each negative electrical contact configured to electrically couple a negative terminal of one of the battery cells;
a plurality of parallel conductors, the parallel conductors configured to electrically couple the battery cells arranged in each battery cell row in parallel with each other; and
a plurality of series conductors, the series conductors configured to electrically couple adjacent battery cell rows in the battery column in series with each other;
a thermally insulating foam block forming a plurality of chambers, each chamber configured to accommodate one of the battery cells; and
an electrical conductor attached to the thermally insulating foam block and corresponding to the battery column,
wherein the current collector is formed as a single, integrated, laminated component,
wherein each of the plurality of battery cells is directly connected to the current collector at a corresponding positive electrical contact and a corresponding negative electrical contact, and
wherein the current collector is attached to the thermally insulating foam block using a pressure sensitive adhesive.
2 . The apparatus of claim 1 , the current collector further comprising:
a plurality of temperature sensors, each temperature sensor configured to sense a temperature associated with a subset of the battery cells.
3 . The apparatus of claim 2 , wherein the plurality of temperature sensors are adhered, laminated, or welded to the current collector.
4 . The apparatus of claim 1 , the current collector further comprising:
a plurality of voltage sense lines, each voltage sense line configured to sense an output voltage associated with a subset of the battery cells.
5 . The apparatus of claim 4 , wherein the plurality of voltage sense lines are adhered, laminated, or welded to the current collector.
6 . The apparatus of claim 1 , wherein the electrical conductor is electrically connected to one of the series conductors.
7 . The apparatus of claim 6 , wherein the electrical conductor is nickel-plated copper.
8 . The apparatus of claim 1 , wherein each positive terminal of the battery cells is welded to a corresponding positive electrical contact of the current collector.
9 . The apparatus of claim 1 , wherein each negative terminal of the battery cells is welded to a corresponding negative electrical contact of the current collector.
10 . The apparatus of claim 1 , wherein the battery cells are respectively bonded, soldered, brazed, or screwed to corresponding positive electrical contacts and negative electrical contacts of the current collector.
11 . The apparatus of claim 1 , further comprising:
a plurality of battery columns.
12 . The apparatus of claim 11 , further comprising:
a plurality of current collectors.
13 . The apparatus of claim 12 , wherein each of the plurality of current collectors corresponds to one of the plurality of battery columns.
14 . The apparatus of claim 12 , wherein the plurality of battery columns and the plurality of current collects are stacked.
15 . The apparatus of claim 12 , wherein the plurality of current collectors are mechanically supported by a common mechanical support.
16 . The apparatus of claim 11 , wherein the current collector corresponds to each of the plurality of battery columns.