Printing with 3D continuous carbon fiber multifunctional composites via UV-assisted coextrusion deposition

Thakur, Aditya R.; Dong, Xiangyang

doi:10.1016/j.mfglet.2020.02.001

Cited by 42 publications

(34 citation statements)

References 27 publications

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“…Furthermore, almost all of these demonstrate poor multifunctional performance, where either the electrical or the mechanical performance is prioritized. For example, Thakur and Dong [27] reported an energy density of 24 Wh kg À1 at an elastic modulus of only 0.29 GPa, whereas Meng et al [28] demonstrated a structural battery material with an elastic modulus of Table 2. Mechanical properties from tensile tests of the structural battery laminates.…”

Section: Multifunctional Performancementioning

confidence: 99%

A Structural Battery and its Multifunctional Performance

Asp

Bouton

Carlstedt

et al. 2021

Adv Energy and Sustain Res

148

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Engineering materials that can store electrical energy in structural load paths can revolutionize lightweight design across transport modes. Stiff and strong batteries that use solid‐state electrolytes and resilient electrodes and separators are generally lacking. Herein, a structural battery composite with unprecedented multifunctional performance is demonstrated, featuring an energy density of 24 Wh kg−1 and an elastic modulus of 25 GPa and tensile strength exceeding 300 MPa. The structural battery is made from multifunctional constituents, where reinforcing carbon fibers (CFs) act as electrode and current collector. A structural electrolyte is used for load transfer and ion transport and a glass fiber fabric separates the CF electrode from an aluminum foil‐supported lithium–iron–phosphate positive electrode. Equipped with these materials, lighter electrical cars, aircraft, and consumer goods can be pursued.

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Section: Multifunctional Performancementioning

confidence: 99%

A Structural Battery and its Multifunctional Performance

Asp

Bouton

Carlstedt

et al. 2021

Adv Energy and Sustain Res

148

View full text Add to dashboard Cite

show abstract

“…This trend is caused by the physical combination between fibers and the polymer melt, indicating that the presence of TPU constrains the displacement of carbon fiber tows during the tensile process, enhancing the strain and improving energy absorption. [25][26][27][28] Furthermore, the control group (without the TPU sheath) exhibits one-time breakage followed by brittleness breakage. The TPU sheath ensures the experimental groups undergoing two-stage fractures, which are separately attributed to the carbon fiber tows that provide mechanical support and the TPU sheath that offers ductility.…”

Section: Resultsmentioning

confidence: 99%

Combination and development of carbon filament tows: Application of coextrusion with long fiber‐reinforced thermoplastics

Lin

Bao

2021

Polymer Composites

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In this study, long fiber-reinforced thermoplastics (LFT) and coextrusion are applied to wrap carbon fiber tows in a thermoplastic polyurethane (TPU) outer layer. In this way, the proposed wrapped yarns have a sheath-core structure.Scanning electron microscopy observation reveals that TPU and carbon fiber tows form a physical combination that allows TPU to further enhance the tensile strength of carbon fiber tows by 35.87%, which is 19.62 ± 1.88 MPa. The tensile strain of carbon fiber tows also improves. LFT and coextrusion are performed to produce successive carbon fiber tows that can be successfully fabricated into textiles, possessing good fabric flexibility. The technique of carbon fiber tows can be applied to mass production feasibility for the field of carbon fiber composites.

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“…A UV laser (200 mW, 405 nm) beam was aimed at a focus spot trailing the coextrusion head with a constant distance of 10 mm to facilitate rapid curing of the coextruded materials while avoiding potential premature clogging. 38 The substrate is mounted onto a rotation table to assist in maintaining the relative position between the laser spot and the coextrusion head throughout the printing process. It is worth noting that the proposed setup could be scaled up using a pellet-based coextrusion deposition method to additively manufacture large-scale structural battery composite components.…”

Section: Methodsmentioning

confidence: 99%

“…In particular, this study investigated SPE coating and cathode doping effects on the 3D printed carbon fiber structural battery composites, including microstructure, printability, electrochemical and mechanical properties, compared to the proof-of-concept in previous studies. 38,39 Electrocoating was first used to produce thin coatings of SPEs onto individual carbon fibers, which were used as both anode and current collectors. The morphology of the SPE coated carbon fibers was further characterized before being coextruded with cathode matrix materials to fabricate structural battery composites.…”

Section: Introductionmentioning

confidence: 99%

Effects of cathode doping on 3D printed continuous carbon fiber structural battery composites by UV-assisted coextrusion deposition

Pappas

Thakur

Dong

2021

Journal of Composite Materials

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Structural battery composites are capable of significant system level mass and volume reductions not possible with separate battery and structural components by simultaneously carrying mechanical loads and storing electrical energy. The ability to 3D print lithium-ion structural batteries in arbitrary geometries would not only allow a flexible battery design but also facilitate its implementation as a structural component. This study presents a new 3D carbon fiber structural battery composite 3D printed by an ultraviolet (UV)-assisted coextrusion deposition method. With individual carbon fibers coated by solid polymer electrolyte (SPE) and dispersed within cathode doped matrix, energy storage is achieved in micro-battery cells at the fiber level within the 3D printed structural battery composite. The 3D printed structural battery composites with various complex geometries are demonstrated by successfully powering up LEDs. The SPE coating and cathode doping effect on microstructure, printability, mechanical and electrochemical properties are further characterized and investigated. A trade-off between printability and electrochemical performance is observed due to hindered curing by the doped cathode materials. The obtained electrochemical and mechanical performance is comparable to the carbon fiber based structural battery composites fabricated by conventional lay-up processes. These well demonstrate the great potentials of the proposed 3D printing method in rapidly fabricating functional structural battery composite components with complex geometries.

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Printing with 3D continuous carbon fiber multifunctional composites via UV-assisted coextrusion deposition

Cited by 42 publications

References 27 publications

A Structural Battery and its Multifunctional Performance

A Structural Battery and its Multifunctional Performance

Combination and development of carbon filament tows: Application of coextrusion with long fiber‐reinforced thermoplastics

Effects of cathode doping on 3D printed continuous carbon fiber structural battery composites by UV-assisted coextrusion deposition

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