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Multifunctional composite materials for energy storage in structural
load paths
Prof. Leif E. Asp and Dr Emile S. Greenhalgh ARPA-E safe energy storage systems for electric vehicles, Denver, Nov 12th 2012
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Introduction – Demands for Energy Storage and Lightweight
• Need to reduce demands of system as whole
City car; 98% of energy associated with weight
Halving weight doubles range
• Adopting composites provide weight savings
Electric vehicles with reasonable range/endurance
• Structural power materials
undertake two roles – electrical energy storage & carry mechanical load.
Volvo electric vehicle
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Multifunctional design of materials
multifunctional material that simultaneously carries mechanical loads whilst storing electrical energy – ‘massless energy’
Multifunctional material
Constituents simultaneously & synergistically undertake two roles
Weztel & Snyder, US Army Research Labs
Multifunctional structure
Distinct constituent components packaged together
J. P. Thomas & M. A. Qidwai, JOM. v57 p18-24. 2005.
introduce multifunctionality in composites structural and non-structural (energy storage capacity) functions
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Structural power design example
Tesla Roadster 1230kg
450kg Battery 780kg Structure/Systems Ω S = 1 Ω E = 0
Ω S = 0 Ω E = 1
Define ΩS= structural efficiency ΩS = 1 implies fully structural (relative to nominal composite) ΩS = 0 implies no structural load bearing capacity
Define ΩE = energy storage efficiency ΩE = 1 implies full electrical energy storage (relative to nominal energy
storage device) ΩE = 0 implies no electrical energy storage
+ =
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700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
0 0.2 0.4 0.6 0.8 1
Syst
em M
ass
(kg)
Structural Efficiency ΩS
1 0.8
0.5 Nominal
Electrical Efficiency ΩE
Structural power design example
Ω s = 1 Ω E = 0
Ω s = ? Ω E = ?
Ω s = 0 Ω E = 1
Structural Power Material
Ωs =ΩE= 1; Ideal multifunctional energy source that can be designed into the structure without any compromise in energy output - Maximum mass saving of 450 kg
Ωs , ΩE < 1 More realistic examples where the structural performance of the energy source leads to a compromise in the energy output
1E SΩ +Ω >
Potential designs to save 180 kg: ΩE = 0.5, ΩS = 0.7 ΩE = 0.8, ΩS = 0.48
Rule of thumb
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Vision and ambition
Driven by novel material design
for future
Lead towards energy efficient, environmentally
friendly materials
multifunctional structural
power composites
Light-weight improve energy
efficiency
Strong carry mechanical
load
Efficient provide energy
storage
Multifunctional save system mass
and volume
Hybrid/ electric vehicles
Aerospace
Portable electronics
Military application
Oil and gas industry
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• Structural Power Materials
New & technically challenging
Potentially huge savings in diverse range of applications
• Interdisciplinary skills required
Electrochemistry, polymer chemistry, mechanical engineering, materials science, physics, chemical engineering
• Spectrum of materials – modify proportion of matrix constituents to change characteristics
Mechanically dominated – e.g. bike frame powering a GPS, (ΩS>ΩE)
Electrically dominated – e.g. shell of a radio controlled aircraft, , (ΩE>ΩS)
Interdisciplinary materials research
Swerea SICOMP first structural battery
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State of the Art
Structural Fuel Cell (ARL)
Structural Supercapacitor (Imperial) NiOH/ZnO Structural Batteries (BAE Systems/Lola)
Li-ion Structural Battery (Swerea SICOMP/KTH)
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Make carbon fibre composites into batteries
Li-ion intercalation in carbon fibre battery electrodes Li-ion transportation in solid polymer electrolyte matrices
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Carbon Fibres – do they have potential for multifunctionality?
Material comparison for min weight designs
0.05
Ti Alloy
Al Alloy
Specific Young’s Modulus(GPa*m3 /kg) 1/3
Mg Alloy
0.02
0.01
0.005
0.002
0.001
5e-4 0.001 0.002 0.005
Steel
Glass Fibre/Thermoset Woven
Carbon Fibre/Thermoset Woven
Carbon Fibre/Thermoset Unidirectional
Aramid Fibre/Thermoset Woven
Spe
cific
stre
ngth
(MP
a*m
3 /kg)
Li+
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Capacity of PAN-based carbon fibres
IMS65 unsized
Similar behaviour as a graphite electrode!
Kjell et al, J Electrochem Soc., 2011
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Impact of electrochemical cycling on the tensile properties of carbon fibres
Jacques et al, 2012
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Structural electrolyte polymer matrix materials
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11
SPE – Effect of crosslink density and Li-salt Thermoset electrolyte SPEs
• Crosslinked PEG methacrylates
• Lithium salt dissolved in monomer mixture prior to cure
• Lithium ions can coordinate to oxygen in the ethylene oxide (EO) unit
OO
O
O
3
O
OO
O
O
6
A:
B:
Mechanical Enhancement
Diffusion Enhancement
Willgert et al, 2011
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Ionic conductivity vs. Modulus
0.1
1
10
100
1000
10000
1E-10
1E-09
1E-08
1E-07
1E-06
1E-05
0 10 20 30 40 50 60 70 80
log
E′ [M
Pa],
20 C
log
[S·c
m-1
]
crosslinking monomer A [%, w/w]
Conductivity E′
• Higher crosslink density gives higher modulus but lower ion transport number
OO
O
O
3
O
OO
O
O
6
A:
B:
Mechanical Enhancement
Diffusion Enhancement
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Conflicting requirements: high polymer mobility improves ion transport but reduces mechanical performance
Innovative SPE matrix materials
Nanostructure to ensure structural robustness whilst allowing ion migration
Microstructures for multifunctional matrices, Imperial
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Device architecture – Structural Battery
Structural Battery (ARL)
Structural Battery (SICOMP)
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• Power Density; fundamental issue Moderate electrodes conductivity, Robust matrix , inhibiting ion migration • Matrix dominated mechanical properties; Dictated by delamination & compression , Additional electrical functionality, Conflicting demands on fibre/matrix interface • Cost and fabrication – principal hurdle for
polymer composites; Structural power materials – make in moisture
free environment (<50ppm), Not amenable to finishing processes (cutting
and drilling) • Ownership Issues; Durability, repair, lifing, recycling, safety, etc
Technical & non-technical needs & bottlenecks
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Opportunities, synergies & common themes • Distributed energy storage for safer road vehicles
• Highly diverse range of potential applications
As performance improves, it has sparked interest from other sectors
• Highly multidisciplinary topic - Electrochemistry & structural materials
Fertile ground for development of new technologies
Novel material architectures - stimulating development of monofunctional electrical & mechanical materials
Solutions for conventional composites - electrical conductivity (lightning strike)
Energy harvesting Lightning strike protection Electrical connections
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Structural Power Materials - Summary Paradigm shift for energy materials Potential to make a considerable difference to how we store
and deliver energy in 2050
Acknowledgements Prof Alexander Bismarck, Prof Anthony Kucernak, Prof Milo Shaffer, Dr Joachim Steinke, Dr Hui Qian,
Dr Natasha Shirshova, Dr Kingsley Ho, Prof Göran Lindbergh, Prof Dan Zenkert, Prof Mats K Johansson, Prof J Varna
Atif Javaid , Tony Carlson, Maria H Kjell, Markus Willgert, Eric Jacques, Andrejs Pupurs, Per-Ivar Sellergren
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Current funding - STORAGE Composite Structural Power Storage for Hybrid Vehicles
• Started January 2010 for 42 months (€3.3M, 9 partners)
• Led by Imperial, who are focusing on supercapacitors . SICOMP leads battery research
• Industrial partners cover the value chain addressing energy demands of future hybrid vehicles
• Demonstrator product will be a booth lid structure (target is 15% weight saving over standard supercapacitor/battery combination)
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Component Design and Implementation
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Questions?
The Economist Professional Engineer
New York Times
Materials world New Scientist
CNBC www.energyopportunities.tv/Editorial-Features/An-energy-storage-revolution