Improving multifunctional behavior in structural electrolytes through copolymerization of structure- and conductivity-promoting monomers

Concepts and Emerging Trends for Structural Battery Electrolytes

The structural battery is a multifunctional energy storage device that aims to address the weight and volume efficiency issues that conventional batteries face, especially in electric transportation. By combining the functions of mechanical load bearing and energy storage, structural batteries can reduce the reliance on, or even eventually replace the main power source in an electric vehicle or a drone. However, one of the key challenges to be addressed before achieving multifunctionality in structural batteries would be the design of a suitable multifunctional structural battery electrolyte. The structural battery electrolyte is the constituent that provides mechanical integrity under flexural loads or impact and hence determines the electrochemical and much of the mechanical performance of a structural battery device. This concept paper aims to cover the key considerations and challenges facing the design of structural battery electrolytes. In addition, the main approaches to surmount these challenges are highlighted, keeping design aspects like sustainability and recyclability in view.

Composite Structural Supercapacitors: High-Performance Carbon Nanotube Supercapacitors through Ionic Liquid Localisation

Composite structural supercapacitors (SSC) are an attractive technology for aerospace vehicles; however, maintaining strength whilst adding energy storage to composite structures has been difficult. Here, SSCs were manufactured using aerospace-grade composite materials and CNT mat electrodes. A new design methodology was explored where the supercapacitor electrolyte was localised within the composite structure, achieving good electrochemical performance within the active region, whilst maintaining excellent mechanical performance elsewhere. The morphologies of these localised SSC designs were characterised with synchrotron X-ray fluorescence microscopy and synchrotron X-ray micro-computed tomography and could be directly correlated with both electrochemical and mechanical performance. One configuration used an ionogel with an ionic liquid (IL) electrolyte, which assisted localisation and achieved 2640 mW h kg⁻¹ at 8.37 W kg⁻¹ with a corresponding short beam shear (SBS) strength of 71.5 MPa in the active area. A separate configuration with only IL electrolyte achieved 758 mW h kg⁻¹ at 7.87 W kg⁻¹ with SBS strength of 106 MPa in the active area. Both configurations provide a combined energy and strength superior to results previously reported in the literature for composite SSCs.

Structural Batteries for Aeronautic Applications—State of the Art, Research Gaps and Technology Development Needs

Radical innovations for all aircraft systems and subsystems are needed for realizing future carbon-neutral aircraft, with hybrid-electric aircraft due to be delivered after 2035, initially in the regional aircraft segment of the industry. Electrical energy storage is one key element here, demanding safe, energy-dense, lightweight technologies. Combining load-bearing with energy storage capabilities to create multifunctional structural batteries is a promising way to minimize the detrimental impact of battery weight on the aircraft. However, despite the various concepts developed in recent years, their viability has been demonstrated mostly at the material or coupon level, leaving many open questions concerning their applicability to structural elements of a relevant size for implementation into the airframe. This review aims at providing an overview of recent approaches for structural batteries, assessing their multifunctional performance, and identifying gaps in technology development toward their introduction for commercial aeronautic applications. The main areas where substantial progress needs to be achieved are materials, for better energy storage capabilities; structural integration and aircraft design, for optimizing the mechanical-electrical performance and lifetime; aeronautically compatible manufacturing techniques; and the testing and monitoring of multifunctional structures. Finally, structural batteries will introduce novel aspects to the certification framework.

Structural Batteries: A Review

Structural power composites stand out as a possible solution to the demands of the modern transportation system of more efficient and eco-friendly vehicles. Recent studies demonstrated the possibility to realize these components endowing high-performance composites with electrochemical properties. The aim of this paper is to present a systematic review of the recent developments on this more and more sensitive topic. Two main technologies will be covered here: (1) the integration of commercially available lithium-ion batteries in composite structures, and (2) the fabrication of carbon fiber-based multifunctional materials. The latter will be deeply analyzed, describing how the fibers and the polymeric matrices can be synergistically combined with ionic salts and cathodic materials to manufacture monolithic structural batteries. The main challenges faced by these emerging research fields are also addressed. Among them, the maximum allowable curing cycle for the embedded configuration and the realization that highly conductive structural electrolytes for the monolithic solution are noteworthy. This work also shows an overview of the multiphysics material models developed for these studies and provides a clue for a possible alternative configuration based on solid-state electrolytes.

High Modulus, Thermally Stable, and Self-Extinguishing Aramid Nanofiber Separators

Mechanically and thermally robust separators offer an alternative approach for preventing battery failure under extreme conditions such as high loads and temperatures. However, the trade-off between electrochemical performance and mechanical and thermal stability remains an ongoing challenge. Here, we investigate aramid nanofiber (ANF) separators that possess high moduli and self-extinguishing characteristics. The ANF separators are formed from the dissolution of bulk Kevlar fibers and their subsequent vacuum-assisted self-assembly. Thermogravimetric analysis shows a high 5 wt % decomposition temperature of 447 °C, which is over ∼175 °C higher than commercial Celgard separators. The ANF separator also possesses a high Young's modulus of 8.8 GPa, which is ∼1000% higher than commercial separators. Even when dry or when soaked in battery electrolyte, the ANF separators self-extinguish upon exposure to flame, whereas commercial separators melt or drip. We show that these features, although adventitious, present a trade-off with electrochemical performance in which a lithium nickel manganse cobalt (NMC) oxide-based battery possessed a reduced capacity of 123.4 mA h g^-1. Considering the separator holistically, we propose that the ANF separator shows an excellent balance of the combined properties of high modulus, flame-resistance, thermal stability, and electrochemical stability and might be suitable for extreme environment applications with further testing.

Multifunctional Epoxy-Based Solid Polymer Electrolytes for Solid-State Supercapacitors

Solid polymer electrolytes (SPEs) have drawn attention for promising multifunctional electrolytes requiring very good mechanical properties and ionic conductivity. To develop a safe SPE for energy storage applications, mechanically robust cross-linked epoxy matrix is combined with fast ion-diffusing ionic liquid/lithium salt electrolyte (ILE) via a simple one-pot curing process. The epoxy-rich SPEs show higher Young's modulus ( E), with higher glass transition temperature ( T_g) but lower ionic conductivity (σ_dc) with a higher activation energy, compared to the ILE-rich SPEs. The incorporation of inorganic robust Al₂O₃ nanowire simultaneously provides excellent mechanical robustness ( E ≈ 1 GPa at 25 °C) and good conductivity (σ_dc ≈ 2.9 × 10^-4 S/cm at 25 °C) to the SPE. This suggests that the SPE has a bicontinuous microphase separation into ILE-rich and epoxy-rich microdomain, where ILE continuous conducting phases are intertwined with a sturdy cross-linked amorphous epoxy framework, supported by the observation of the two T_gs and low tortuosity as well as the microstructural investigation. After assembling the SPE with activated carbon electrodes, we successfully demonstrate the supercapacitor performance, exhibiting high energy and power density (75 W h/kg at 382 W/kg and 9.3 kW/kg at 44 W h/kg). This facile strategy holds tremendous potential to advance multifunctional energy storage technology for next-generation electric vehicles.

Facile Synthesis of Unique Cellulose Triacetate Based Flexible and High Performance Gel Polymer Electrolyte for Lithium Ion Batteries

Lithium ion batteries (LIBs) with polymer based electrolytes have attracted enormous attention due to the possibility of fabricating intrinsically safer and flexible devices. However, economical and eco-friendly sustainable technology is an oncoming challenge to fulfill the ever increasing demand. To circumvent this issue, we have developed a gel polymer electrolyte (GPE) based on renewable polymers like cellulose triacetate and poly(polyethylene glycol methacrylate) p(PEGMA) using a photo polymerization technique. Cellulose triacetate offers good mechanical strength with improved ionic conductivity, owing to its ether and carbonyl functional groups. It is observed that the presence of an open network has a critical impact on lithium ion transport. At room temperature, GPE PC exhibits an optimal ionic conductivity of 1.8 × 10^-3 S cm^-1 and transference number of 0.7. Interestingly, it affords an excellent electrochemical stability window up to 5.0 V vs Li/Li⁺. GPE PC shows a discharge capacity of 164 mAhg^-1 after the first cycle when evaluated in a Li/GPE/LiFePO₄ cell at 0.5 C-rate. Interfacial compatibility of GPE PC with lithium metal improves the overall cycling performance. This system provides a guiding principle toward a future renewable and flexible electrolyte design for flexible LIBs (FLIBs).

Multifunctional structural energy storage composite supercapacitors

This paper addresses the challenge of producing multifunctional composites that can simultaneously carry mechanical loads whilst storing (and delivering) electrical energy. The embodiment is a structural supercapacitor built around laminated structural carbon fibre (CF) fabrics. Each cell consists of two modified structural CF fabric electrodes, separated by a structural glass fibre fabric or polymer membrane, infused with a multifunctional polymeric electrolyte. Rather than using conventional activated carbon fibres, structural carbon fibres were treated to produce a mechanically robust, high surface area material, using a variety of methods, including direct etching, carbon nanotube sizing, and carbon nanotubein situgrowth. One of the most promising approaches is to integrate a porous bicontinuous monolithic carbon aerogel (CAG) throughout the matrix. This nanostructured matrix both provides a dramatic increase in active surface area of the electrodes, and has the potential to address mechanical issues associated with matrix-dominated failures. The effect of the initial reaction mixture composition is assessed for both the CAG modified carbon fibre electrodes and resulting devices. A low temperature CAG modification of carbon fibres was evaluated using poly(3,4-ethylenedioxythiophene) (PEDOT) to enhance the electrochemical performance. For the multifunctional structural electrolyte, simple crosslinked gels have been replaced with bicontinuous structural epoxy–ionic liquid hybrids that offer a much better balance between the conflicting demands of rigidity and molecular motion. The formation of both aerogel precursors and the multifunctional electrolyte are described, including the influence of key components, and the defining characteristics of the products. Working structural supercapacitor composite prototypes have been produced and characterised electrochemically. The effect of introducing the necessary multifunctional resin on the mechanical properties has also been assessed. Larger scale demonstrators have been produced including a full size car boot/trunk lid.

Multifunctional structural supercapacitor composites based on carbon aerogel modified high performance carbon fiber fabric

A novel multifunctional material has been designed to provide excellent mechanical properties while possessing a high electrochemical surface area suitable for electrochemical energy storage: structural carbon fiber fabrics are embedded in a continuous network of carbon aerogel (CAG) to form a coherent but porous monolith. The CAG-modification process was found to be scalable and to be compatible with a range of carbon fiber fabrics with different surface properties. The incorporation of CAG significantly increased the surface area of carbon fiber fabrics, and hence the electrochemical performance, by around 100-fold, resulting in a CAG-normalized specific electrode capacitance of around 62 F g(-1), determined by cyclic voltammetry in an aqueous electrolyte. Using an ionic liquid (IL) electrolyte, the estimated energy density increased from 0.003 to 1 Wh kg(-1), after introducing the CAG into the carbon fiber fabric. 'Proof-of-concept' multifunctional structural supercapacitor devices were fabricated using an IL-modified solid-state polymer electrolyte as a multifunctional matrix to provide both ionic transport and physical support for the primary fibers. Two CAG-impregnated carbon fabrics were sandwiched around an insulating separator to form a functioning structural electrochemical double layer capacitor composite. The CAG-modification not only improved the electrochemical surface area, but also reinforced the polymer matrix surrounding the primary fibers, leading to dramatic improvements in the matrix-dominated composite properties. Increases in in-plane shear strength and modulus, of up to 4.5-fold, were observed, demonstrating that CAG-modified structural carbon fiber fabrics have promise in both pure structural and multifunctional energy storage applications.