Ultra-thin Carbon Fiber Battery Electrodes for Structural Aircraft Applications

Solution Overview

Problem

Current batteries, particularly lithium-based ones, are limited by their energy density, mechanical fragility, and inability to serve as structural components due to their compactness and weight constraints, which hinders their use in applications like electric vehicles and aircraft where space and weight are critical, and their charging rates are not industrially feasible.

Innovation Solution

The development of a battery cell with a thin carbon fiber ply, less than 90 micrometers thick, integrated into the anode or cathode, providing high mechanical resistance and flexibility, allowing the battery to assume both energy storage and mechanical functions, with a solid-state polymer electrolyte for efficient charging, and a thin separator for compactness and rapid charging.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If conventional battery structures are used, then energy storage capacity is achieved, but volume and weight remain too large for applications like aircraft

Engineering Contradiction:

Improveenergy densityVSAvoidbattery volume

Core Design Contradiction:

Use of energy by moving objectVSVolume of moving object

Solution Approach 1:

The patent employs ultra-thin carbon fiber plies (less than 90 micrometers thick) as electrode structures, replacing conventional thick battery components. These thin film structures achieve high energy density while dramatically reducing battery volume and weight, making them suitable for aircraft applications where space is critical.

Inventive Principle:

Principle #30Flexible shells and thin films

2Use of energy by moving object

If conventional battery structures are used, then energy storage capacity is achieved, but weight remains too high for applications like aircraft

Engineering Contradiction:

Improveenergy densityVSAvoidbattery weight

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The patent employs ultra-thin carbon fiber plies (less than 90 micrometers thick) as electrode structures, replacing conventional thick battery components. These thin film structures achieve high energy density while dramatically reducing battery volume and weight, making them suitable for aircraft applications where space is critical.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent uses carbon fiber composite materials for the electrode plies. Carbon fiber provides an excellent strength-to-weight ratio and high electrical conductivity, enabling the battery to achieve high energy density with minimal weight, which is crucial for aircraft applications.

Inventive Principle:

Principle #40Composite materials

3Strength

If conventional battery structures are used, then basic mechanical integrity is maintained, but mechanical strength is insufficient for structural applications

Engineering Contradiction:

Improvemechanical strengthVSAvoidbattery reliability under stress

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses carbon fiber composite materials for the electrode plies. Carbon fiber provides an excellent strength-to-weight ratio and high electrical conductivity, enabling the battery to achieve high energy density with minimal weight, which is crucial for aircraft applications.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent designs the battery to serve dual functions: energy storage and structural support. The ultra-thin carbon fiber plies provide both electrochemical performance and mechanical strength, allowing the battery to function as both an energy source and a structural component in aircraft applications.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Volume of moving object

If thin carbon fiber plies are used, then volume and weight are reduced, but manufacturing precision becomes more challenging

Engineering Contradiction:

Improvebattery volumeVSAvoidply thickness control

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent specifies a precise thickness parameter for the carbon fiber plies (less than 90 micrometers), which balances the need for reduced volume with manufacturability. This parameter optimization ensures that the battery achieves compact dimensions while remaining feasible to manufacture with current industrial capabilities.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The battery achieves a higher energy density, improved mechanical properties, reduced weight, and faster charging, enabling its use as a structural component in vehicles and aircraft while meeting aeronautical safety standards.

Implementation Method 1

the distance to travel for the electrons between an anode and an electrode is short and therefore the charging duration of such battery is beneficially short

Methodology Applied

Scientific EffectElectron conduction: Conduction (electrical)

Implementation Method 2

with a solid-state polymer electrolyte for efficient charging

Methodology Applied

Scientific EffectIon transport: Fast Ion Conductor

Data Source

PatentUS11075384B2Battery cell comprising an ultra thin layer of carbon fibers

Publication Date: 2021.07.27 AIRBUS DEFENCE & SPACE GMBH

AI summary

A battery cell includes an anode, a cathode, and a separator between the anode and the cathode, wherein at least one of the anode or the cathode includes at least a carbon fiber ply comprising carbon fibers, the carbon fiber ply having a thickness of less than 90 micrometers. Also disclosed are a battery and an aircraft including such battery cell, and a method for manufacturing such battery cell.