Carbon Fiber Structural Battery for Lighter Electric Mobility Frames
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Solution Overview
Problem
Conventional battery packs in electric mobility devices and sensors disrupt weight balance and occupy valuable space, limiting battery capacity and travel distance due to their weight and size constraints.
Innovation Solution
Integration of a structural battery with a continuous carbon fiber core, a mechanically compliant electrolyte, and a composite cathode, which provides energy storage while maintaining structural support, reducing overall weight and size by distributing energy storage throughout the device's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a traditional battery pack is installed in an e-bike or e-scooter, then energy storage capacity is provided, but overall weight increases and weight balance is disturbed
Solution Approach 1:
The patent combines the structural frame and battery into a single integrated component. The carbon fiber frame itself serves as the battery housing and structural support, eliminating the need for separate battery packs. This merging of structure and energy storage function reduces overall weight while maintaining energy storage capacity.
Solution Approach 2:
The carbon fiber frame performs multiple functions simultaneously: it provides structural support, weight reduction, and energy storage capacity. By making the frame multi-functional, the patent eliminates the need for additional dedicated battery components, thereby reducing overall system weight.
2Quantity of substance
If a battery pack is mounted in limited locations on the frame, then energy storage is achieved, but weight balance and space availability are compromised
Solution Approach 1:
The patent segments the battery into multiple smaller cells distributed throughout the carbon fiber frame structure. This segmentation allows energy storage to be distributed across multiple locations rather than concentrated in one place, improving weight balance while maintaining total battery capacity.
Solution Approach 2:
Different sections of the carbon fiber frame are designed with varying battery cell densities based on local weight balance requirements. Areas requiring more counterweight have higher battery density, while other areas have lower density, optimizing overall weight distribution.
3Weight of moving object
If carbon fiber is used solely for structural support, then weight is reduced, but energy storage capability is not provided
Solution Approach 1:
The carbon fiber frame is designed to perform dual functions: structural support and energy storage. By integrating battery cells directly into the frame structure, the same component provides both mechanical strength and energy storage capability, eliminating the need for separate battery packs.
Solution Approach 2:
The patent merges the structural frame function with the energy storage function into a single integrated system. The carbon fiber frame is not just a housing for batteries but actively contains and structures the battery cells, combining two previously separate functions into one unified component.
4Reliability
If a separate battery housing is added to protect the battery, then safety is improved, but overall weight and volume increase
Solution Approach 1:
The battery housing function is merged with the carbon fiber frame structure. The frame itself serves as the protective housing, eliminating the need for an additional separate battery case. This integration maintains battery protection while minimizing overall device volume.
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
This solution achieves significant weight savings of up to 25-35% and extends the utility of carbon fiber composite materials by providing both structural support and energy storage, enhancing the performance and efficiency of electric mobility devices and sensors.
Implementation Method 1
a continuous carbon fiber core
Implementation Method 2
a mechanically compliant electrolyte
Data Source
AI summary
An electric mobility apparatus that can include at least one electric carbon fiber component. The electric carbon fiber component incorporating a structural battery, the structural battery including energy storage devices, each of the energy storage devices having an anode core of a continuous carbon fiber, an electrolyte arranged on the at least one continuous carbon fiber core, and a cathode layer arranged to the continuous carbon fiber core on the electrolyte. An interface is electrically connected to the structural battery, the interface for inputting power for charging the structural battery and for outputting power.