FR2774513A1 - Sleeve for battery element for space vehicles, satellites or probes - Google Patents

Abstract

The sleeve (30) for the battery is made of thermally conductive graphite fibres laid in the same direction and supported in an electrically insulating adhesive such as an epoxy resin. The sleeve is placed over a tubular cylinder (22) which terminates in a base flange (48) with fixing holes (60) round its periphery. The flange provides a thermal bridge from the graphite fibres to the mounting.

Description

 The present invention relates generally to improved systems intended for mounting batteries on spacecraft in order to ensure their integrity, their proper functioning, and a long service life. Throughout this description, the expression "spacecraft" will be used in the generic sense to refer to spacecraft of all types, whether they are launch vehicles, space stations, satellites, space probes, or other vehicles that can be used in a space environment.

 Nickel-hydrogen batteries and other varieties of chemical batteries for spacecraft are typically mounted in the structure of the spacecraft by means of a plurality of cylindrical metallic sleeves which receive individual battery cells by supporting them. The functions of the sleeves are to (a) physically connect each cell to the battery structure and (b) conduct the heat lost due to the operation of the element to the base plate of the battery and from there to spacecraft heat rejection system (for example, an optical space radiator).

 Many metals have been proposed and used for the manufacture of sleeves for battery cells. These included aluminum, beryllium, magnesium and alloys of these metals. In reality, aluminum is the most commonly used metal for this purpose. All these materials meet the technical requirements which want them to have a high thermal conductivity, an appropriate unit strength, a generally correct fatigue resistance, and a low density. As is customary in all space-related activities, weight is an important consideration when designing and constructing battery cell sleeves, so that materials other than metals which have all the characteristics indicated above while being of a significantly lower weight.

 In recent years, composite materials have increasingly become the materials of choice to replace metals in applications that require mechanical strength and low weight.

Composite materials, or "composites", incorporate groups of elongated fibers of resistant materials embedded in a pasty amorphous matrix which then solidifies and binds the fibers together forming a resistant assembly. This matrix can be polycyanate, mixtures of epoxy and polycyanate, or other suitable materials which have a high bond strength, are light in weight, and do not have unfavorable characteristics, for example flaking forming particles floating freely in space.

 Graphite is a first example of a material which exhibits remarkable thermal conductivity, in particular in the form obtained by pyrolysis and a low density (-2 g / cm2). In reality, any solid fiber can be used for this purpose, having an extremely high thermal conductivity. Pure graphite, however, is extremely fragile and, for this reason, its use as a sleeve material has not previously been seriously considered. An additional limitation to the use of graphite, of a non-technical but economically important nature comes from the fact that it can only be produced in shaped parts from solid monoblocks by means of expensive machining.

 We will present a number of examples which are representative of the prior art relating generally to this technological field.

 U.S. Patent No. 5,310,141, issued May 10, 1994 to Homer et al., Describes cylindrical battery cells connected to each other by forming multiple assemblies by pairs of sleeve half shells. conduct heat preferably in an axial direction, each set of sleeves is mounted on a heat rejection plate for direct radiation into space.

 U.S. Patent No. 5,096,788, issued March 17, 1992 to Bresin et al. Describes a battery assembly having a housing and a plurality of elements within the housing, each element having a positive terminal and a negative terminal, and a flexible circuit interconnecting the plurality of elements, a biasing device ensuring appropriate contact between the flexible circuit and the terminals of the elements.

 U.S. Patent No. 4,828,022, issued May 9, 1989 to Koeler et al., Describes a heat conductive sleeve designed to fit around a cylindrical heat source such as a battery for use in a satellite. The design is chosen so as to obtain the optimum compromise between the heat transfer capacity of the sleeve and its weight for a given application.

 US Patent No. 4,420,545, issued December 13, 1983 to Meyer et al., Describes a metal-gas pressurized battery, emphasizing the reduction in weight and volume. End plates axially compress the electrode stack and support it radially inside the pressure vessel.

This reduces the stresses applied to the stack during the vibrations and the cycling of the elements.

The stack is not linked to the pressure container at any point in the battery, but is an autonomous assembly which is confined only by the limit of the container.

 U.S. Patent No. 4,346,151, issued August 24, 1982 to Uba et al., Describes a sealed multiple cell rechargeable battery, comprising a one-piece, open-mouth container formed of a plurality of cell holders. cup-shaped connected to each other at mutual tangent zones, electrochemical cells of the rechargeable type adapting in the cell supports and being interconnected to form the battery, and a closing element fixed to the mouth of the container monobloc.

 The concept of using thermally conductive graphite fibers as a lightweight material for a nickel-hydrogen element sleeve is the subject of U.S. Patent No. 5,510,208, issued April 23, 1996 to Hall et al. In this prior invention, a cylinder of axially oriented graphite-epoxy fibers is reinforced on the inner and outer surfaces by a graphite-epoxy laminate of a right-angle crisscross structure, and replaces a conventional aluminum part. In order to allow interface compatibility with the aluminum part, the graphite-epoxy part comprises, fixed to the latter by adhesives, elements intended to clamp the cylinder on the element and to structurally integrate the assembly of element sleeve thus formed to other element sleeve assemblies. The cylinder is partially divided in the axial direction to form a mortise which allows movement for radial compression.

 It is in view of the state of the art that we have just described that the present invention has been conceived, and has now been put into practice.

 In accordance with the present invention, a battery cell sleeve assembly includes a continuous tubular sleeve extending between proximal and distal ends, and includes a plurality of elongated thermally conductive fibers extending longitudinally in substantially unidirectional fashion, having conductivity thermal which is not less than that of aluminum, embedded in a suitable matrix. The sleeve is received on the outer peripheral surface of a tubular battery cell which is typically, but not necessarily cylindrical, and in contiguous relationship with the battery cell. A tubular base member having a peripheral flange is attached to the continuous tubular sleeve so that the distal ends of the thermally conductive fibers are contiguous with the peripheral flange. With this design, the peripheral flange functions as a thermal bridge to extract heat from the continuous tubular sleeve by conduction between the thermally conductive fibers and the peripheral flange. In a first embodiment, the thermally conductive fibers are made of graphite, and the continuous tubular sleeve is between 0.254 mm and 6.35 mm (0.010 and 0.25 inch) thick and is composed of approximately 60 W of fibers and 40 of adhesive in volume. An electrically insulating adhesive, such as an epoxy, a loaded epoxy, polycyanate, charged polycyanate is applied to the interface between the continuous tubular sleeve and the tubular base element in a bond, or nominal thickness, ordered from 0.127 mm (5 thousandths of an inch). After having secured the battery element and the continuous tubular sleeve, the battery element is charged. This causes the battery element to pressurize, which, in turn, expands its outer periphery, so that it is more firmly in contact with the continuous tubular sleeve.

Thus, the present invention reiterates the teachings of patent NO 5,510,208 with respect to the use of low density, high thermal conductivity graphite fibers as a desirable first material for the construction of element sleeves. Graphite fibers have favorable thermal conductivities of up to 1,100
W / mK when compared to graphite obtained by pyrolysis (k> 2000 W / mK) and to pure aluminum (k = 230
W / mK). Furthermore, and more importantly, unidirectional fiber bundles can be embedded in a suitable matrix (epoxy, polycyanate, epoxy-cyanate mixtures) to form thin sheets that can be shaped. Such sheets can, for example, easily be formed into a tube suitable for use as an element sleeve.

In the present invention, however, the following improvements are taught over the composite sleeve design described in the U.S. Patent
Unis NO 5 510 208. First of all, rather than fixing the divided tubular sleeve to the element using mechanical fasteners whose mounting points are linked to the sleeve, a continuous sleeve (not divided) is connected to the element not loaded with adhesive. The clamping effect between the element and the cylinder is further obtained by loading the element, which in turn puts the element under pressure and causes its lateral dimensions to grow against the internal surface of the tubular sleeve.

This design change reduces cost and weight.

 In addition, since the tubular sleeve no longer needs to be divided, the inner layer of right-angled interleaving graphiteepoxy reinforcement from the previous embodiment can be eliminated. This inner layer was necessary to prevent buckling with split cylinders. However, this component is not necessary for an undivided tubular sleeve and, furthermore, its other structural functions are satisfied by the element which is now structurally bonded to the inner peripheral surface of the sleeve. This feature reduces cost and weight, and slightly improves the thermal performance of the element sleeve since the internal structural layer of the prior art creates a thermal impedance between the element's heat source and the path. heat removal of graphite from the sleeve.

 In addition, at the junction between the tubular sleeve and the lower mounting tab, the adhesive seal is modified through the use of an electrically insulating charged epoxy or other suitable adhesive material, forming a controlled bonding of the 0.127 mm (0.005 inch). The effect of this design is to electrically isolate the cell sleeve from the spacecraft. In the prior art, this function has been ensured by the use of a layer of rubber or electrically insulating plastic film between the element and the internal peripheral surface of the cylinder. Thanks to this new approach, the rubber layer or plastic film can be removed, thus saving weight.

 Such arrays of unidirectional graphite fibers thus laminated with a suitable matrix meet the thermal requirements of an element sleeve assembly for a spacecraft, in that they will function to conduct heat from the electrochemical element to 'to the spacecraft radiator.

 In fact, the unidirectional thermal layers provide the required conductive properties which, until now, have been provided by an isotropic metallic sleeve.

 In practice, the structures of the invention were manufactured with graphite fibers K1100 from the brand AMOCO. The graphite fibers are oriented either at 00 or +/- 150 with respect to the longitudinal axis of the element. Such layers are typically 0.127 mm (0.005 inch) thick and composed of 60% fiber and 40 Oc of resin by volume. The required thermal conductivity is obtained through the use of a sufficient number of compensated layers with regard to their inclination off the axis.

 The need to provide the mechanical and thermal interface of the element sleeve with other elements of the battery and with the spacecraft has been addressed by appropriately bonding machined aluminum parts to the heterogeneous fiber-matrix structure. described above as necessary to achieve thermal and mechanical interfaces with the spacecraft. Thus, at the base of the fiber-matrix sleeve there is an overlapping connection with a concentric aluminum cylinder which serves as a mechanical and thermal interface with the base plate of the battery. The overlap is made along an axial length of approximately 2.54 cm (1 inch), with an adhesive thickness of between approximately 0.025 mm and 0.127 mm (0.001 inch and 0.005 inch). This design guarantees a secure mechanical interface and low heat flow through the bonding joint with low thermal conductivity.

 Likewise, aluminum mechanical elements can be linked to the external peripheral surface of the continuous sleeve in order to mechanically connect the element to adjacent elements for improved mechanical integrity.

 Other features, advantages and additional benefits of the invention will become apparent from the following description taken in conjunction with the following drawings. It should be understood that the foregoing general description and the following detailed description are by way of example and explanation and should not limit the invention. The accompanying drawings, which are incorporated into and form part of the invention, illustrate one of the embodiments of the invention and, in association with the description, serve to explain the principles of the invention in general terms. Identical reference numerals refer to identical parts throughout the description.

 Figure 1 is a perspective view schematically illustrating, for a spacecraft, a battery system incorporating the present invention.

 Figure 2 is a perspective view of a single battery cell sleeve assembly embodying the present invention and used in the battery system illustrated in Figure 1.

 Figure 3 is a sectional view, taken generally along line 3-3. of Figure 2, showing, in more detail, part of the battery cell sleeve assembly illustrated in Figure 2.

 FIG. 3A is a detailed sectional view illustrating in more detail a part of FIG. 3.

FIG. 3B is a detailed sectional view illustrating in more detail another part of FIG. 3, and
FIG. 4 is a graph comparing the performance of the graphite-epoxy design of the battery cell sleeve assembly of the invention with that of the aluminum design of the prior art.

 We will now turn to the drawings and, initially, to FIG. 1 which illustrates in a simplified manner a battery system 20 intended for use in a spacecraft and implementing the concepts of the present invention. A plurality of battery cell sleeve assemblies 22 are mounted in a manner which will be described on a base plate 24 which may be made of aluminum honeycomb, for example. The base plate 24 serves as an overall thermal bridge for extracting heat from each of the sleeve assemblies 22. Next, the heat is extracted from the base plate 24 and supplied to a suitable optical space radiator 26 via an appropriate heat transfer element 28, also shown in simplified form. The optical space radiator is positioned on the opposite side to the honeycomb panel of the base plate and faces the deep space, i.e. a low temperature sink.

 The design features of the battery cell sleeve assemblies 22 which embody the invention are more clearly shown in Figures 2, 3 and 3A. Figure 2 shows a continuous tubular fiber-matrix sleeve assembly 22 according to the invention, for a battery cell 23 with a diameter of 89 mm (3.5 inches), which is typically cylindrical and has opposite rounded ends. It is used to replace an aluminum sleeve (of the prior art) intended for the same battery element. The inventive fiber muff sleeve assembly may weigh approximately 165 g, for example, while the prior art aluminum sleeve assembly weighs approximately 325 g. As shown in Figure 4, the two sleeve assemblies have equivalent thermal performance. In this regard, each battery element sleeve assembly 22 may be provided with a suitable heating element 64, mounted on the outer peripheral surface of the thermal sleeve 30 and covering it.

 The precise design of the sleeve assembly 22 will now be described with particular reference to Figures 2, 3 and 3A. The thermal sleeve 30 extends between proximal and distal ends 34, 36 of the sleeve assembly 22, and has a plurality of elongated first fibers extending longitudinally substantially unidirectionally 38 of low density material, high conductivity, embedded in a matrix 40 which can be made of polycyanate, mixtures of epoxy and polycyanate, or other suitable binder materials. Aluminum is the desirable benchmark for the physical characteristics of the sleeve assembly. That is, the fibers 38 are chosen so that the sleeve assembly 22 has a thermal conductivity equal to that of a sleeve made of aluminum, and a weight substantially less than that of a sleeve made of aluminum.

The fibers are preferably graphite fibers, an example commercially available being fibers
K1100 of the brand AMOCO, the graphite fibers being oriented either at 0 or at +/- 150 with respect to the longitudinal axis of the element. Such layers typically have a thickness of 0.127 mm (0.005 inch) and are composed of 60 fibers and 40 W of epoxy by volume. The required thermal conductivity can be obtained by using a sufficient number of compensated layers with regard to their inclination off the axis. One could also use any other commercially available fiber with an extremely high thermal conductivity (K> 800 W / mK).

 The thermal sleeve 30 has a thickness of between about 0.254 and 6.35 mm (0.010 and 0.25 inch) and is received in contiguous relationship on the outer peripheral surface 42 of the battery cell 23. Adhesive 46 ( Figure 3A) or other suitable bonding agent is interposed between the thermal sleeve 30 and the external surface 42 in order to fixedly join these components according to the relationship illustrated in Figure 2. It may be desirable for certain applications that a layer 47 of suitable insulation in the form of a heat-shrinkable film covers the external peripheral surface 42 of the battery element 23. In this case, as illustrated in FIG. 3A, it would be necessary for the adhesive 46 to effectively cover the insulating layer 47.

 Turning now to FIGS. 2, 3 and 3B, a tubular base element 48, still probably made of aluminum, has a raised edge 50 for reception therein of the distal end 36 of the thermal sleeve 30 As seen in Figure 3B, a suitable adhesive 52 is used to bond the outer surface of the thermal sleeve 30 to the inner peripheral surface 54 of the raised flange 50 of the base member 48. The adhesive 52 preferably comprises electrically insulating charged epoxy or other suitable adhesive material, forming a defined bond thickness of not less than about 0.127 mm (0.005 inch). In this way, the thermal sleeve 30 is securely electrically isolated from the spacecraft. The lower external surface of the thermal sleeve 30 is contiguous with the internal peripheral surface 54 of the raised rim 50 of the base element 48.

Thanks to this design, the thermal fibers 38 are contiguous to the raised rim 50, so that the raised rim serves as a thermal bridge to extract heat from the thermal sleeve by conduction between the fibers 38 and the raised rim.

 Considered as a whole, and with particular regard to FIG. 3, the sleeve assembly 22 defines a recess 56 intended for the reception therein of the battery element 23.

 The base member 48 also includes an outer peripheral flange 58 (Figure 3) which is appropriately drilled, as at 60, at a plurality of locations spaced equally around the circumference to receive threaded fasteners 58 allowing it to be securely mounted on the base plate 24. It is within the scope of the invention that the peripheral flange 58 is oriented inward, being provided for stability, a plurality of legs oriented outwards, spaced around the circumference, being provided for mounting on the base plate.

 The sleeving and base assembly of fibersmaterial / aluminum 22. has the additional advantage over the sleeves of the prior art made entirely of aluminum of being intrinsically doubly insulated, since the aluminum is hard anodized and the surface of the thermal sleeve 30 is made of pure adhesive.

This provides additional protection against electrical faults.

 Although a preferred embodiment of the invention has been described in detail, those skilled in the art will appreciate that various other modifications may be made to the illustrated embodiments without departing from the scope of the invention as described in the specification and defined in the appended claims.

Claims (19)

RESELL I CAT I ONS  1. Battery cell sleeve assembly (22) comprising  a continuous thermal sleeve (30) extending between proximal and distal ends and having a longitudinal axis, composed of a plurality of elongated thermally conductive fibers (38) extending longitudinally in a substantially unidirectional manner embedded in a matrix (40), said thermal sleeve (30) being received on the external peripheral surface of a battery element (23) in contiguous relationship with the latter, and  a base member (48) having a flange (50) for receiving thereon said distal end of said thermal sleeve, said distal end of said thermal sleeve being contiguous with said flange, whereby said flange functions as a bridge thermal to extract heat from said thermal sleeve by conduction between said thermally conductive fibers and said flange.  2. Battery element sleeve assembly (22) according to claim 1  wherein said thermally conductive fibers have a thermal conductivity which is not less than that of aluminum.  3. battery element sleeve assembly (22) according to claim 1,  wherein said thermally conductive fibers are graphite fibers, and  wherein said thermal sleeve has a thickness of between about 0.254 and 6.35 mm (0.010 and 0.25 inch) and is composed of about 60% fiber and 40 W of matrix by volume.  4. The battery cell sleeve assembly of claim 1 comprising  connecting means (46) for fixedly joining said thermal sleeve to the outer peripheral surface of the battery cell.  5. A battery cell sleeve assembly according to claim 1 comprising  connecting means (52) for fixedly joining said thermal sleeve to said base member.  6. Battery cell sleeve assembly according to claim 5  wherein said connecting means comprises an electrically insulating charged adhesive forming a defined bond thickness which is not less than about 0.127 mm (0.005 inch).  7. Battery cell sleeve assembly (22) comprising  a continuous thermal sleeve (30) extending between proximal and distal ends and having a longitudinal axis, composed of a plurality of elongated thermally conductive fibers (38) extending longitudinally substantially unidirectionally of a low density material and high conductivity, said thermally conductive fibers being embedded in a matrix (40), and  a base member (48) comprising an annular flange for receiving thereon said distal end of said thermal sleeve, said distal end of said thermal sleeve being contiguous with said flange, whereby said flange functions as a thermal bridge for extracting heat from said thermal sleeve by conduction between said thermally conductive fibers and said flange.  8. Battery cell sleeve assembly (22) comprising  a continuous thermal sleeve (30) extending between proximal and distal ends and having a longitudinal axis, and composed of a plurality of elongated thermally conductive fibers (38) extending longitudinally substantially unidirectionally which are embedded in a matrix ( 40), and  a base member (48) having an annular raised rim for receiving thereon said distal end of said thermal sleeve, said distal end of said thermal sleeve being contiguous with said rim, whereby said rim functions as a thermal bridge for extracting heat from said thermal sleeve by conduction between said thermally conductive fibers (38) and said flange (50).  9. A method of manufacturing a battery cell structure comprising the steps of:  (a) providing a continuous thermal sleeve (30) extending between proximal and distal ends and having a longitudinal axis, composed of a plurality of elongated substantially longitudinally extending thermally conductive fibers (38) which are embedded in an adhesive matrix (40),  (b) attaching the thermal sleeve to the outer peripheral surface of a cylindrical battery cell (23) in contiguous relationship therewith, and  (c) fixing a base element (48) comprising a flange (50) on the thermal sleeve for reception thereon of the distal ends of the thermal sleeve which are contiguous to the flange, whereby said flange functions as a thermal bridge for extracting heat from the thermal sleeve by conduction between the thermally conductive fibers and the flange.  10. The method of claim 9 comprising the step of:  (d) applying an electrically insulating adhesive to the interface between the thermal sleeve and the cylindrical base element.  11. The method of claim 10  wherein the adhesive applied in step (d) is an epoxy forming a defined bond thickness which is not less than about 0.127 mm (0.005 inch).  12. The method of claim 9 comprising the step of:  (e) charging the battery cell, thereby pressurizing the battery cell, and enlarging its outer circumference so that it is more firmly in contact with the thermal sleeve.  13. Battery system (20) including  a plurality of battery cell sleeve assemblies (22) mounted on a base plate (24), said base plate being an assembly thermal bridge for extracting heat from each of said battery sleeve assemblies battery cell, and  a space radiator (26) thermally connected to said base plate in order to radiate the heat coming from the latter in deep space,  wherein each of said battery cell sleeve assemblies comprises  a continuous thermal sleeve (30) extending between proximal and distal ends and having a longitudinal axis, composed of a plurality of elongated thermally conductive fibers (38) extending longitudinally in a substantially unidirectional manner which are embedded in a matrix (40 ), said thermal sleeve (30) being received on the external peripheral surface of a battery element (23) in contiguous relationship with the latter,  a base member (48) having a flange (50) for receiving thereon said distal end of said thermal sleeve, said distal end of said thermal sleeve being contiguous with said flange, whereby said flange functions as a bridge thermal to extract heat from said thermal sleeve by conduction between said thermally conductive fibers (38) and said flange (50).  14. Battery cell sleeve assembly according to claim 1  wherein said base member (48) includes a base peripheral flange (58) for mounting on a base plate (24), as well as an integral upright tubular flange (50) to which said thermal sleeve (30) is bonded .  15. Battery element sleeve assembly according to claim 7  wherein said base member (48) includes a base peripheral flange (58) for mounting on a base plate (24), as well as an integral upright tubular flange (50) to which said thermal sleeve is bonded.  16. The battery cell sleeve assembly of claim 8  wherein said base member (48) includes a base peripheral flange (58) for mounting on a base plate (24), as well as an integral upright tubular flange (50) to which said thermal sleeve (30) is bonded .  17. The battery cell sleeve assembly of claim 13  wherein said base member (48) includes a base peripheral flange (58) for mounting on a base plate (24), as well as an integral upright tubular flange (50) to which said thermal sleeve (30) is bonded .  18. Battery element sleeve assembly (22) for a spacecraft, comprising  a continuous thermal sleeve (30) extending between proximal and distal ends and having a longitudinal axis, composed of a plurality of elongated thermally conductive fibers (38) extending longitudinally substantially unidirectionally which are embedded in a matrix (40 ), said thermal sleeve (30) being received on the external peripheral surface of a battery element (23) in contiguous relation thereto, and  a base element (48) integral with said distal end of said thermal sleeve (30) comprising a base peripheral flange (58) mounting said thermal sleeve on a base plate (24) connected to a space radiator (26) intended to radiate heat from the latter to the deep space, whereby said base peripheral flange (58) functions as a thermal bridge to extract heat from said thermal sleeve (30) by conduction between said thermally conductive fibers (38) and said base peripheral flange (58).  19. Battery element sleeve assembly (22) according to claim 18  wherein said thermally conductive fibers (38) have a thermal conductivity which is not less than that of aluminum.