# US 2023/0054839 A1 · Light weight thermal runaway and explosion resistant aerospace battery > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2023/0054839 A1 - Document ID: US20230054839A1 - Status: Published application - Kind: A1 - Application number: 17/405,887 - Filed: 2021-08-18 - Published: 2023-02-23 - Earliest claimed: 2021-08-18 - Assignees: Rolls-Royce Singapore Pte. Ltd.; ROLLS-ROYCE plc - Applicants: Rolls-Royce Singapore Pte. Ltd.; Rolls-Royce plc - Inventors: Michael Adam Zagrodnik; Teh Yee Siang; Mathivanan Anand Prabhu; Krishnamoorthi Sivalingam; Stephen Mountain - Web page: https://patentgrep.com/patent/US20230054839A1 ## CPC - H01M 50/211: adapted for pouch cells - H01M 50/24: adapted for protecting batteries from their environment, e.g. from corrosion (thermal insulation H01M10/658) - H01M 10/613: Cooling or keeping cold - H01M 10/625: Vehicles - H01M 10/653: characterised by electrically insulating or thermally conductive materials - H01M 10/6555: arranged between the cells - H01M 10/6557: arranged between the cells - H01M 10/658: by thermal insulation or shielding - H01M 50/222: Inorganic material - H01M 50/231: having a layered structure - H01M 50/249: specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64) - H01M 2220/20: Batteries in motive systems, e.g. vehicle, ship, plane - Y02E 60/10: Energy storage using batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract An aerospace battery may include a housing and a battery pack core. The housing may include a thin dual layer casing. The battery pack core is disposed in the housing and may include at least one cell district that includes a plurality of pouch cell batteries. A ceramic material may surround the at least one cell district and a closed cell foam may fill open space between the ceramic material and the housing. ## Claims ### Claim 1 An aerospace battery comprising: a housing; a battery pack core disposed in the housing, wherein the battery pack core comprises: a district comprising a plurality of pouch cell batteries; and a ceramic jacket surrounding the district; and a closed cell foam disposed in the housing, wherein at least a portion of the closed cell foam is disposed between the battery pack core and the housing. ### Claim 2 (depends on 1) The aerospace battery of claim 1, wherein the housing comprises: an outer layer comprising at least one of aluminum, an aluminum alloy, a steel alloy, titanium, or a titanium alloy; and an inner layer comprising a ceramic paper. ### Claim 3 (depends on 1) The aerospace battery of claim 1, wherein the housing comprises an arc-shaped casing cover. ### Claim 4 (depends on 3) The aerospace battery of claim 3, wherein the arc-shaped casing cover comprises: an outer layer comprising at least one of aluminum, an aluminum alloy, a steel alloy, titanium, or a titanium alloy; and an inner layer comprising a ceramic paper. ### Claim 5 (depends on 3) The aerospace battery of claim 3, wherein the arc-shaped casing cover defines an aperture configured to vent heat and gases from the housing. ### Claim 6 (depends on 1) The aerospace battery of claim 1, wherein the closed cell foam comprises a fire retardant and a polymer foam. ### Claim 7 (depends on 1) The aerospace battery of claim 1, wherein the closed cell foam comprises a viscoelastic material configured to bond to the housing and the ceramic jacket. ### Claim 8 (depends on 1) The aerospace battery of claim 1, wherein the ceramic jacket comprises an alumina-silicate or a calcium magnesium silicate. ### Claim 9 (depends on 1) The aerospace battery of claim 1, wherein the district comprises a first district of a plurality of districts, each respective district comprising a respective plurality of pouch cell batteries, and wherein the ceramic jacket comprises a first ceramic jacket of a plurality of ceramic jackets, each respective ceramic jacket surrounding a respective district of the plurality of districts. ### Claim 10 (depends on 9) The aerospace battery of claim 9, wherein at least a portion of the closed cell foam is disposed between each adjacent ceramic jacket of the plurality of ceramic jackets and between the plurality of ceramic jackets and the housing. ### Claim 11 (depends on 1) The aerospace battery of claim 1, wherein the battery pack core comprises a retaining seat configured to support the plurality of pouch cell batteries in the housing. ### Claim 12 (depends on 1) The aerospace battery of claim 1, wherein the plurality of pouch cell batteries comprises a first pouch cell battery and a second pouch cell battery, wherein the district further comprises a cold plate dispose between the first pouch cell battery and the second pouch cell battery, wherein the cold plate comprises flexible, polymer pouch defining a cooling channel. ### Claim 13 (depends on 12) The aerospace battery of claim 12, wherein the cold plate is configured to, during operation of the battery pack core, regulate a temperature of the first pouch cell battery and the second pouch cell battery and electrically isolate the first pouch cell battery and the second pouch cell battery. ### Claim 14 (depends on 12) The aerospace battery of claim 12, wherein the cold plate is configured to, during operation of the battery pack core, conform to dimensional changes of the first pouch cell battery and the second pouch cell battery. ### Claim 15 (depends on 12) The aerospace battery of claim 12, wherein the cold plate comprises a first cold plate, wherein the district further comprises: a second cold plate adjacent to the first pouch cell battery, opposite the first cold plate; and a third cold plate adjacent to the second pouch cell battery, opposite the first cold plate. ### Claim 16 (depends on 12) The aerospace battery of claim 12, wherein the battery pack core comprises a retaining seat configured to support the plurality of pouch cell batteries and the cold plate in the housing, wherein the cold plate defines a cooling channel having an inlet and an outlet, and wherein the retaining seat defines a fluid delivery channel configured to couple to the inlet of the cooling channel of the flexible cold plate and a fluid return channel configured to couple to the outlet of the cooling channel of the flexible cold plate. ### Claim 17 (depends on 1) The aerospace battery of claim 1, further comprising a battery management system comprising: a printed circuit board defining apertures configured to receive therethrough respective cell tabs of each respective pouch cell battery of the plurality of pouch cell batteries; and a busbar integrated with the printed circuit board and configured to couple with the respective cell tabs. ### Claim 18 A method comprising: inserting a battery pack core within a housing of an aerospace battery, wherein the battery pack core comprises: a district comprising a plurality of pouch cell batteries; and a ceramic jacket surrounding the district; and reactive molding a closed cell foam within the housing around the battery pack core, wherein the closed cell foam fills substantially all the space between the housing and the battery pack core. ### Claim 19 (depends on 18) The method of claim 18, wherein the district comprises a first district of a plurality of districts, each respective district comprising a respective plurality of pouch cell batteries, wherein the ceramic jacket comprises a first ceramic jacket of a plurality of ceramic jackets, each respective ceramic jacket surrounding a respective district of the plurality of districts, and wherein the method further comprises inserting the plurality of districts into a retaining seat to form the battery pack core. ### Claim 20 (depends on 18) The method of claim 18, wherein the method further comprises electrically coupling each pouch cell battery of the plurality of pouch cell batteries to a battery management system comprising: a printed circuit board defining apertures configured to receive therethrough respective cell tabs of each respective pouch cell battery; and a busbar integrated with the printed circuit board and configured to couple with the respective cell tabs.