High performance shape-adjustable structural lithium-ion battery based on hybrid fiber reinforced epoxy composite

High performance shape-adjustable structural batteries with both excellent electrochemical performances and mechanical properties, and compatible with conventional batteries and composite processing techniques, are highly attractive for next generation electrical vehicles and electrical aircrafts. Herein, a high-performance structural lithium-ion battery composite (SLBC) is developed by encapsulating commercial-available battery core materials with hybrid fiber reinforced epoxy composite laminate shells, which can be assembled into desired irregular shapes with the conventional vacuum bagging technique. Firstly, the laminate shell layout with the combination of glass fiber woven fabric (GFWF) and carbon fiber woven fabric (CFWF) is designed and optimized. Meanwhile, a PET film is employed to wrap the battery core materials, which enables processing of the SLBC with liquid electrolyte in ambient condition. The SLBC obtained demonstrates both prominent mechanical (flexural strength of 211.7 MPa and flexural modulus of 7.7 GPa) and electrochemical properties (an initial discharge capacity of 98.5 mAh/g at 0.2C, a high energy density of 314.5 Wh kg−1, and a good cycling performance) owing to the hybrid design of CFWF and GFWF as well as a sealed environment to guarantee the battery operate well. Impressively, the in-situ mechano-electrochemical measurements are assessed under the out-of-plane compressive stress and the flexural stress conditions. These results show that the SLBC under loading can maintain stable electrochemical performance even at a high out-of-plane compressive stress of 20 MPa and a high flexural stress of 150 MPa. Furthermore, the SLBC can also maintain the excellent discharge capacity when subjected to a high impact energy, which is promising in next generation electrical vehicles. Finally, the wave-like SLBC fabricated demonstrates the effectiveness in withstanding loads and driving electric fan simultaneously, which is promising in next generation electrical vehicles..