Lightweight and Thermally Resistant Battery Containment System

Physical Sciences Inc. (PSI) and Wichita State University (WSU) are proposing a lightweight fire resistant composite containment system to improve aircraft safety for electronic Vertical Take-off and Landing (eVTOL) platforms.  High voltage Lithium-ion batteries increase power system efficiencies to meet eVTOL emerging demands; however, these battery systems are high risk for thermal runaway and propagation to neighboring cells, modules, and aircraft structures.  Recent high profile Li-ion battery fires/explosion incidents have driven new containment system designs.  These designs rely on the use of steel alloys that still do not withstand all possible peak fire and peak temperature battery cook-off scenarios.  The proposed PSI solution is based on a refractory composite material that is 4X lighter than steel, and capable of withstanding prolonged exposure to over 2000 ºF.  In the Phase I program, thermal & structural modeling, based on temperature and pressure data associated with actual Li-ion thermal runaway failure scenarios, will be used to guide test specimen design and testing protocol. Composite prototypes will then be fabricated and burner rig tested to demonstrate the thermal capability of the system to contain an event to improve battery system survivability and prevent aircraft damage.