Thermal State Studying of the Battery Module with Various Thermal Control Systems for Application as a Part of the Aircraft Hybrid or Electric Power Plant

Aeronautical and Space-Rocket Engineering


Аuthors

Teterin R. O.*, Edigarev A. D., Shemet M. V.

UEC-Klimov, 11, Kantemirovskaya Str., Saint-Petersburg, 194100, Russia

*e-mail: teterin_ro@klimov.ru

Abstract

The current evolution of aviation technologies demonstrates a consistent transition from conventional internal combustion engines towards hybrid and electric propulsion systems (EPS) for aircraft. This transition opens new opportunities for innovative flying vehicle architectures, driven by goals of reducing emissions, improving energy efficiency, and minimizing acoustic and thermal characteristics. Lithium-ion batteries (LIBs) play a central role in the of electric and hybrid-electric aircraft architecture due to their high specific power and energy density. However, their integration poses significant challenges, especially in terms of thermal management and ensuring safe operation under stringent aviation constraints.
The LIBs performance and service life are highly sensitive to the operating temperature. Deviation from the optimal thermal range (15–35°C) leads to the capacity fade, accelerated degradation, and in extreme cases, thermal runaway, which may pose serious safety risks. The demand for high power at critical flight phases such as takeoff and landing exacerbates these thermal challenges. In contrast to electric vehicles, where peak power is required for rather short durations, aircraft typically requires sustained high-power output over longer periods (30–300 seconds), increasing the risk of overheating.
To address this, an effective Battery Thermal Management System (BTMS) is essential. Among various BTMS technologies there are air cooling, indirect liquid cooling, phase change materials, and heat pipes. The direct liquid immersion cooling offers the most effective solution for the aviation-grade battery systems. With this method, battery cells are being directly submerged into a dielectric coolant, eliminating thermal contact resistance and ensuring superior heat dissipation. Immersion cooling to the safety as well by suppressing the effects of thermal runaway and allowing compact module architecture.
This study presents the design and thermal analysis of lithium-ion battery modules with immersion cooling tailored for hybrid-electric aircraft applications. The modules are based on high-power cylindrical 21700 cells with a capacity of less than 10 Ah, selected for their superior structural integrity and safety features such as Current Interrupt Devices (CID). The thermal model accounts for the LIB cells anisotropic thermal conductivity, and was verified against experimental discharge data at 5°C and 10°C rates. Three battery module architectures were developed and compared in terms of their thermal performance under high current loads.
The simulation results demonstrate that immersion-cooled modules effectively maintain cell temperatures below the critical threshold of 55 °C, ensuring full utilization of available energy without compromising safety or cycle life. This validates immersion cooling as a promising approach for aviation battery systems. The presented design strategies align with the strict requirements of aerospace standards (such as RTCA DO-311A) and reflect the increasing adoption of modular, fault-tolerant battery architectures in the next-generation electric aircraft.

Keywords:

aircraft power plant, energy sources, hybrid power plant, battery module, thermal management system

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