‘Structural batteries’ for longer EV range

These light, carbon-fibre batteries could boost EVs and electronic devices

Spotted: Battery demand for EVs grows larger every year as efforts to reduce transport emissions ramp up. At the same time, battery sizes are also increasing as manufacturers look to improve range, running counter to the idea that reducing an EV’s weight is a key way to boost its efficiency. To address this, researchers at Chalmers University in Sweden have developed a carbon fibre composite battery that could change the way energy is stored in vehicles and other electronic devices. 

The innovation, called a ‘structural battery’, combines the structural integrity of carbon fibre with the energy storage capabilities of lithium-ion technology, allowing the battery to function as both a power source and a load-bearing material. This means that the structural battery can form part of the vehicle or device casing, significantly reducing the overall weight.

The carbon fibre acts as the battery’s electrode, further eliminating the need for additional materials and mass. Theoretical simulations suggest that this new form of energy storage could enable EVs to drive up to 70 per cent farther on a single charge. What’s more, devices like mobile phones and laptops could become thinner and lighter. 

“Our research is unique because (…) we are not just focused on improving multifunctional performance but are innovating the entire concept of what a structural battery can be,” postdoctoral researcher Richa Chaudhary and Research lead Professor Leif Asp told Springwise. The structural battery builds on previous research demonstrating the functionality of carbon fibre electrodes, and this latest iteration has an energy density of 30 watt-hours per kilogramme. Although lower than conventional li-ion batteries, it’s more than compensated by the reduced weight of the overall system.

While the battery is still in the development phase, Chalmers Ventures and the researchers have spun out a company, Sinonus AB, to further explore its commercial potential. The initial commercial focus is on smaller electronics like laptops and mobile phones, but heavier industries such as EVs are also on the horizon.

The next steps involve continuing to improve the energy density and mechanical properties while also developing safer, more sustainable chemistries to complement the structural battery’s safer design. As Professor Asp and Chaudhary told Springwise, the team plans to continue making improvements and “pushing the limits of multifunctional energy storage by collaborating across disciplines and potential industries, exploring scalable manufacturing techniques, and pursuing applications that can have a direct impact on industries such as automotive and aerospace.”

Written By: Oscar Williams