Jacketed Structural Battery with Glass-Fiber Polyester Layer
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Solution Overview
Problem
Conventional batteries for vehicles, particularly in air and space travel, face challenges in maximizing energy storage density, leading to heavy and large batteries due to their low charge-to-mass ratio, necessitating the development of structural batteries with enhanced energy density and load-bearing capabilities.
Innovation Solution
A laminated energy storage system comprising multiple layers, including electrically conductive layers, carbon-fiber-reinforced plastic, glass-fiber-reinforced plastic, and LiFePO4, jacketed with glass-fiber-filled polyester, where the LiFePO4 to carbon fiber ratio is optimized, and the jacketing layer is coated with metal or ceramic for added protection, allowing for bonding of individual batteries for increased structural integrity and energy storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional batteries are used to maximize energy storage, then electrical energy storage increases, but battery weight increases due to low charge-to-mass ratio
Solution Approach 1:
The patent merges the structural load-bearing function with the energy storage function by integrating battery cells directly into the vehicle body structure. The battery cells replace traditional structural components, creating a unified system where the energy storage device simultaneously provides mechanical support, thereby eliminating redundant structural weight while maximizing energy capacity.
Solution Approach 2:
The patent employs composite material structures where battery cells are integrated with structural components. This creates a hybrid system combining the electrochemical properties of battery materials with the mechanical properties of structural materials, achieving both high energy density and load-bearing capability in a single integrated component.
2Weight of moving object
If battery size is reduced to decrease weight, then battery weight decreases, but energy storage capacity decreases
Solution Approach 1:
The patent transitions from traditional three-dimensional bulk battery structures to two-dimensional planar or laminated battery configurations. This dimensional change allows for increased surface area to volume ratio, enabling higher energy capacity within a reduced weight constraint by distributing battery cells across multiple planes rather than concentrating them in a single volumetric space.
3Strength
If structural batteries with load-bearing function are developed, then mechanical strength increases, but manufacturing complexity increases
Solution Approach 1:
The patent divides the structural battery system into modular segments or individual battery cells that can be independently manufactured and then assembled into the final structural configuration. This segmentation allows for simplified production of individual components using standard battery manufacturing processes, while the overall structural integrity is achieved through the systematic arrangement and connection of these modular units.
Data Source
AI summary
A battery with a layers including a first layer which is electrically conductive, a second layer consisting essentially of carbon-fiber-reinforced plastic, a third layer of glass-fiber-reinforced plastic, a fourth layer of carbon-fiber-reinforced plastic and LiFePO4, where the ratio by weight of LiFePO4 to carbon fiber is from 2:1 to 2.5:1, and a fifth layer which is electrically conductive, wherein the battery has substantially been jacketed by a layer made of glass-fiber-filled polyester.