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

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The EPSRC Future Composites Manufacturing Hub