Monolithic Composite Structural Battery for Weight Reduction
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Solution Overview
Problem
Current rechargeable batteries, particularly lithium ion batteries, face limitations due to their size, weight, and vulnerability to common substances like water and carbon dioxide, requiring protective casings and additional support structures that reduce efficiency and pose safety hazards.
Innovation Solution
A monolithic composite structural component integrating rechargeable lithium ion batteries with anode, cathode, and separator structures formed from composite materials, including electrically conductive fibers and electrochemically active materials, where these structures serve both structural and electrochemical roles, eliminating the need for separate casings and support structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lithium ion batteries are housed in hermetically sealed protective casings to prevent contact with water, oxygen and carbon dioxide, then battery safety and performance are improved, but device weight and volume increase
Solution Approach 1:
The patent merges the protective casing function with the battery electrode structures by using the same composite material for both containment and electrochemical activity. The battery components are integrated directly into the structural component without separate protective housing, eliminating redundant materials and reducing overall weight while maintaining safety through the inherent properties of the composite material.
Solution Approach 2:
The composite material serves multiple functions simultaneously: it acts as the structural component, the protective casing, and the active battery electrode. This multi-functionality eliminates the need for separate protective housings and support structures, directly addressing the weight and volume concerns while maintaining safety and performance.
2Reliability
If conventional batteries include separate support structures such as casing, packaging, separators, and current collectors, then battery reliability and manufacturability are improved, but volumetric and gravimetric efficiency decrease
Solution Approach 1:
The patent combines multiple separate battery components (electrodes, separators, current collectors) into a single integrated composite structure. The fibrous composite material simultaneously serves as electrode, separator, and current collector, eliminating the need for separate support structures and significantly improving volumetric and gravimetric efficiency.
Solution Approach 2:
The invention uses fibrous composite materials that inherently provide both structural support and electrochemical functionality. The composite structure replaces conventional separate components with a unified material system that maintains reliability while reducing volume and weight.
3Ease of manufacture
If lithium ion batteries use conventional separate component design with casing and support structures, then ease of manufacture and repair are improved, but device weight and complexity increase
Solution Approach 1:
The patent merges manufacturing steps by creating a single integrated composite component that serves multiple functions. Instead of assembling separate battery components and protective casings, the entire battery system is manufactured as one monolithic structure, simplifying both manufacturing and reducing component complexity.
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 design enhances gravimetric and volumetric efficiency, improves mechanical properties, and provides safer, more compact power sources with reduced weight, suitable for applications like aircraft and unmanned aerial vehicles, while allowing for integration into various components without additional bulk or weight.
Implementation Method 1
anode structure and the cathode structure are each formed from a composite material which includes electrically conductive fibres and electrochemically active material
Implementation Method 2
separator structure which separates the anode from the cathode and contains an electrolyte
Data Source
Figure 1
AI summary
According to the invention there is provided a component including a rechargeable battery and a method of producing same. The component uses lithium ion chemistry and the battery has an anode structure, a cathode structure, and a separator structure which separates the anode from the cathode and contains an electrolyte. The anode structure and the cathode structure are each formed from a composite material which includes electrically conductive fibres and electrochemically active material in a binder matrix and the battery is formed to be structurally inseparable from the rest of the component.