Carbon Fiber Structural Battery Electrodes for Weight and Volume Limits

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Solution Overview

Problem

Conventional lithium-ion batteries lack sufficient strength characteristics, limiting their application in devices that require both energy storage and structural support, such as micro-unmanned aerial vehicles, where larger batteries are needed for increased endurance but result in increased weight and size.

Innovation Solution

Development of structural batteries that integrate energy storage and structural support using carbon fiber-reinforced polymer electrodes with metallic tabs embedded within, combined with a liquid electrolyte, allowing for both high energy storage and structural integrity in a single component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If conventional lithium-ion batteries are used to increase energy storage capacity, then endurance is improved, but weight and volume increase

Engineering Contradiction:

ImproveenduranceVSAvoidweight

Core Design Contradiction:

Duration of action of moving objectVSWeight of moving object

Solution Approach 1:

The patent combines the battery electrode with structural components by integrating carbon fiber reinforcement directly into the electrode structure. The carbon fiber serves dual purposes: providing structural support and acting as the electrode material itself, eliminating the need for separate structural components and reducing overall weight while maintaining energy storage capacity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials consisting of carbon fiber reinforcement combined with conductive polymers or coatings to create electrodes that possess both high strength mechanical properties and high energy storage capacity. This composite approach allows the electrode to function as both a structural component and an energy storage element, resolving the contradiction between weight and endurance.

Inventive Principle:

Principle #40Composite materials

2Duration of action of moving object

If conventional lithium-ion batteries are used to increase energy storage capacity, then endurance is improved, but volume increases

Engineering Contradiction:

ImproveenduranceVSAvoidvolume

Core Design Contradiction:

Duration of action of moving objectVSVolume of moving object

Solution Approach 1:

The patent merges the functions of structural support and energy storage into a single integrated component. The carbon fiber-reinforced electrode serves as both the structural framework and the active energy storage element, eliminating the need for separate structural components and reducing the overall volume occupied by the battery system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The carbon fiber-reinforced electrode performs multiple functions simultaneously: it provides structural support, conducts electricity, and stores energy. This multi-functionality allows the same material to fulfill multiple roles that traditionally required separate components, thereby reducing volume while maintaining endurance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Use of energy by moving object

If liquid electrolyte is used to achieve acceptable energy storage properties, then energy storage is improved, but strength characteristics deteriorate

Engineering Contradiction:

Improveenergy storageVSAvoidstrength characteristics

Core Design Contradiction:

Use of energy by moving objectVSStrength

Solution Approach 1:

The patent employs composite materials where carbon fiber reinforcement is integrated with the electrode structure. The carbon fiber provides high strength mechanical properties while the conductive polymer or coating enables energy storage functionality. This composite approach resolves the contradiction by allowing the electrode to maintain structural integrity while achieving acceptable energy storage properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the physical and chemical parameters of the electrode material by incorporating carbon fiber reinforcement and conductive coatings. These parameter changes enhance both the mechanical strength and the energy storage capacity of the electrode, allowing it to withstand structural demands while maintaining electrochemical performance.

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 integration of energy storage and structural support in a single component reduces the overall weight and volume of devices, enhancing their endurance and aerodynamic performance while eliminating the need for separate structural components.

Implementation Method 1

The electrolyte allows for lithium ion migration between the two electrodes of the battery

Methodology Applied

Scientific EffectIon migration: Diffusion

Implementation Method 2

carbon fiber-reinforced polymer electrodes with metallic tabs embedded within

Methodology Applied

Scientific EffectComposite material reinforcement: Composite Materials

Data Source

PatentUS11855273B2Structural lithium-ion batteries with carbon fiber electrodes

Publication Date: 2023.12.26 THE MITRE CORPORATION

AI summary

Described are structural electrode and structural batteries having high energy storage and high strength characteristics and methods of making the structural electrodes and structural batteries. The structural batteries provided can include a liquid electrolyte and carbon fiber-reinforced polymer electrodes comprising metallic tabs. The structural electrodes and structural batteries provided can be molded into a shape of a function component of a device such as ground vehicle or an aerial vehicle.