Carbon Fiber Reinforced Lithium-Ion Battery Composites with Higher Mechanical Strength: Multifunctional Power Integration for Structural Applications

Indiana University-Purdue University Indianapolis (IUPUI)This study proposes and evaluates a multi-functional carbon fiber reinforced composite with embedded Lithium-ion battery for its structural integrity concept. The comparison of versatile composite structures manufactured conventionally, air-sprayed and electrospun multi walled carbon nano tubes in order to discover a better packaging method for incorporating lithium-ion batteries at its core is determined. In the electrospinning process recognized globally as a flexible and cost-effective method for generating continuous Nano filaments. It was incorporated exactly on the prepreg surface to obtain effective inter-facial bonding and adhesion between the layers. The mechanical and physical properties of carbon fiber reinforced polymers (CFRP) with electrospun multi walled carbon nano tubes (CNTs) have evidenced to possess higher mechanical strength incorporated between the layers of the composite prepreg than the traditional CFRP prepreg composite, At the same time the air sprayed CFRP with CNTs offers mechanical strength more than the traditional CFRP prepreg but lesser than the electrospun. This can be a design consideration from the economic feasibility viewpoint. They also contribute to efficient load transfer and structural load bearing implementation without compromising the chemistry of battery. The design validation, manufacture methods, and experimental characterization (mechano-electrical) of Multi-functional energy storage composites (MESCs) are examined. Experimental results on the electrochemical characterization reveal that the MESCs show comparable performance to the standard lithium-ion pouch cells without any external packaging and not under any loading requirements. The mechanical performance of the MESC cells especially electrospun CFRP is evaluated from three-point bending tests with the results demonstrating significant mechanical strength and stiffness compared to traditional pouch cells and conventional, air-sprayed CFRP and at lowered packaging weight and thickness. This mechanical robustness of the MESCs enable them to be manufactured as energy-storage devices for electric vehicles