Situation

• Conventional Li-ion drones suffer from low energy density, limiting range and flight endurance.
• Adoption of Lithium-Sulfur (Li-S) batteries directly into the airframe for weight efficiency.
• Li-S cells demand high-strength, active-pressure packaging due to low rigidity and high electrolyte volume.

Task

• Design of a lightweight mechanism for uniform pressure delivery via casing elasticity.
• Development of multifunctional components with embedded Phase Change Materials (PCM) for autonomous stability.

Action

• Engineering of high-strength plates for active pressure through elastic restoration during assembly.
• Application of buffer structures for stress distribution and PCM integration for thermal shielding.

Result

• Capacity retention improvement of 65% (fade reduced from 17% to 6%) over 500 cycles.
• Elimination of external cooling/pressing hardware through structural BMS integration.
• Secured impact resistance and established rapid module-level maintenance systems.