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Carbon fiber-based structural lithium-ion batteries are attracting significant attention in the automotive and aerospace industries due to their dual capability of energy storage and mechanical load-bearing, leading to weight reduction. These batteries utilize lightweight carbon fiber (CF) composites, which offer excellent stiffness, strength-to-weight ratios, and electrical conductivity. Polyacrylonitrile-based CFs, comprising graphitic and amorphous carbon, are particularly suitable for Li-ion battery applications as they allow the storage of lithium ions. However, integrating lithium iron phosphate (LFP) into CFs poses challenges due to complex lab-scale processes and the use of toxic dispersants, hindering large-scale industrial compatibility. To address this, we investigate the development of water-based LFP-integrated CF structural Li-ion batteries. Homogeneous suspensions are created using cellulose nanocrystals (CNCs) to form hybrid structures. The battery system employs LFP-modified CF as the cathode, unsized CF as the anode, and a water-based electrolyte. The LFP-CNC-graphene nanoplatelet (GNP) hybrids are coated onto CFs through immersion coating. Scanning electron microscopy (SEM) images confirm the well-dispersed and well-adhered LFP-CNC-GNP structures on the CF surface, contributing to their mechanical interlocking and electrochemical performance. The batteries demonstrate a specific energy density of 62.67 Wh/kg and a specific capacity of 72.7 mAh/g. Furthermore, the cyclic voltammetry experiments reveal the stability of the LFP-CNC-GNP-coated CF batteries over 200 cycles without degradation. This research enables the engineering of hybrid nanostructured battery laminates using novel LFP-CNC-GNP-coated CFs, opening avenues for the development of innovative Li-ion structural batteries.
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This content will become publicly available on June 1, 2026
Ultrasonic Spray Coating of Carbon Fibers for Composite Cathodes in Structural Batteries
Structural batteries, also known as “massless batteries”, integrate energy storage directly into load-bearing materials, offering a transformative alternative to traditional Li-ion batteries. Unlike conventional systems that serve only as energy storage devices, structural batteries replace passive structural components, reducing overall weight while providing mechanical reinforcement. However, achieving uniform and efficient coatings of active materials on carbon fibers remains a major challenge, limiting their scalability and electrochemical performance. This study investigates ultrasonic spray coating as a precise and scalable technique for fabricating composite cathodes in structural batteries. Using a computer-controlled ultrasonic nozzle, this method ensures uniform deposition with minimal material waste while maintaining the mechanical integrity of carbon fibers. Compared to traditional techniques such as electrophoretic deposition, vacuum bag hot plate processing, and dip-coating, ultrasonic spray coating achieved superior coating consistency and reproducibility. Electrochemical testing revealed a specific capacity of 100 mAh/gLFP with 80% retention for more than 350 cycles at 0.5 C, demonstrating its potential as a viable coating solution. While structural batteries are not yet commercially viable, these findings represent a step toward their practical implementation. Further research and optimization will be essential in advancing this technology for next-generation aerospace and transportation applications.
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- Award ID(s):
- 2050956
- PAR ID:
- 10658052
- Publisher / Repository:
- MDPI
- Date Published:
- Journal Name:
- Electrochem
- Volume:
- 6
- Issue:
- 2
- ISSN:
- 2673-3293
- Page Range / eLocation ID:
- 13
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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