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Manufacturing for structural applications of multifunctional
composites Prof Paul Robinson†, Prof Ivana Partridge ‡, Prof Emile S. Greenhalgh †,
Prof Milo Shaffer †, Prof Anthony Kucernak †, Dr Dmity Ivanov ‡, Prof Kevin Potter ‡†Imperial College London, UK; ‡University of Bristol
Summary of core project aims
To explore, develop and evaluate manufacturing processes for multifunctional composite structures
• Structural power composites • Multifunctionality through hybrid tufting and 3-D printing of enhanced resin
Multifunctional composites?
•Two approaches:
–Implanting of secondary materials or deviceswithin a parent material (often referred to as smart structures / materials)
J. P. Thomas & M. A. Qidwai. "The design & application of multifunctional structure-battery
materials systems." JOM. v57 p18-24. 2005.
Jacques E., et.al, ElectrochemistryCommunications, Volume 35, 2013, Pages 65-67.
–Constituents perform two very differentroles (truly multifunctional materials)
• Composite structures and materials which simultaneously perform more than one function.
Why multifunctional composites?• By simultaneously performing more than one function,
a successful multifunctional composite system will outperform a system with separate sub-systems for each function.
E-Fan 1.0 (500kg, MTOW 600kg)
333 kg Structure/Systems
s = 1 E = 0
E = 0, Standard structure, which has no electrical energy storage
s = 0, Standard power source does not have any structural
capabilities
167kg Battery
s = 0 E = 1
Background
Structural powerOverview of Conventional Energy Storage
1.E-02
1.E-01
1.E+00
1.E+01
1.E+02
1.E+03
1.E-05 1.E-04 1.E-03 1.E-02 1.E-01 1.E+00 1.E+01 1.E+02 1.E+03
Al caps
Al/Organic
caps
Su
pe
rca
pa
cito
rs
Energy Density (Wh/kg)
Po
we
r D
en
sity (
kW
/kg
)
1.E-02
1.E-01
1.E+00
1.E+01
1.E+02
1.E+03
1.E-05 1.E-04 1.E-03 1.E-02 1.E-01 1.E+00 1.E+01 1.E+02 1.E+03
Al caps
Al/Organic
caps
Su
pe
rca
pa
cito
rs
Energy Density (Wh/kg)
Po
we
r D
en
sity (
kW
/kg
)
Background: Structural powerSupercapacitors
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+
++
+
++++
+
+
++
+
+
+++
++++++++
++++++++++
+
++
+++++++++++++
+ -
Ion permeable
Separator (Insulator) Current collector
(Electrode)
Electrolyte
Conventional Supercapacitor
Insulator; Glass Fibre Mat
Electrodes: ActivatedCarbon Fibre Mat
Electrolyte: Nanostructured bicontinuous polymer
Structural Supercapacitor
Background: Structural powerComposite supercapacitors development
1st Generation –ACF/PEGDGE
G=0.00001Wh/kg P=0.14W/kg
E~25GPa
2nd Generation–CF/CNT/ Bi-cont. Epoxy/IL
G=0.0089Wh/kg P=0.0021W/kg
E~60GPa; G12~0.5GPa
Conventional supercapacitor
G=2.9Wh/kg & P=6900W/kg
Structural; G=0.2Wh/kg; P=18W/kg & G12~0.6GPa
Semi-structural; G=1.0Wh/kg; P=290W/kg
3rd Generation – CF/CAG/Bi-cont. Epoxy/IL
Background: Structural powerTechnology demonstrators (N.B. without CAG)
Full scale Volvo S80 boot lid incorporating 16 structural supercapacitor cells.
Model car body curved composite supercapacitor .
Background: Hybrid tufting
Insertion of threads through the thickness of dry preform
‘Thread’ types
Background: Hybrid tufting• Combining classical continuous reinforcement fibres with thin metal wires and/or
thermoplastic fibres via microbraiding
• Electrical conductivity, thermal conductivity, sensing
• Stabilise preforms with printed skeleton
• Enhance through-thickness conductivity
Background: 3D printing of enhanced resin
• Change failure mechanisms
Core project
Summary of core project aims
To explore, develop and evaluate manufacturing processes for multifunctional composite structures
• Structural power composites • Multifunctionality through hybrid tufting and 3-D printing of enhanced resin
Core project activities• Structural power composites • Multifunctionality through
hybrid tufting and 3-D printing of enhanced resin
Develop manufacturing processes that integrate multifunctional capabilities within structuralconfigurations such as doubly-curved surfaces, sandwich panels, and plates with stiffeners and frames
Address the implications for multifunctional composite component design throughout the life cycle including reproducibility, cost, production rate, repairability and end-of-life disposal.
PhD projects: specific structural embodiment of a multifunctional capability for a particular industrial application.
e.g. design and infusion for a secondary structure fuselage access panel with electrical energy storage capability based on supercapacitors
e.g. integration of hybrid tufting / 3-D printing of enhanced resin in structurally representative features
Industrial involvement• Structural power composites • Multifunctionality through
hybrid tufting and 3-D printing of enhanced resin
Develop manufacturing processes that integrate multifunctional capabilities within structuralconfigurations such as doubly-curved surfaces, sandwich panels, and plates with stiffeners and frames
Address the implications for multifunctional composite component design throughout the life cycle including reproducibility, cost, production rate, repairability and end-of-life disposal.
PhD projects: specific structural embodiment of a multifunctional capability for a particular industrial application.
e.g. design and infusion for a secondary structure fuselage access panel with electrical energy storage capability based on supercapacitors
e.g. integration of hybrid tufting / 3-D printing of enhanced resin in structurally representative features
Other multifunctional composites?
Morphing composite structures
• Self-repair using vascular architectures
Shape memory composites
• Structural health monitoring
Please contact us
The EPSRC Future Composites Manufacturing Hub
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