Dual function energy-storing supercapacitor-based carbon fiber composite for body panels of a vehicle

Patent metadata

Field	Value
Publication number	US-12354796-B2
Application number	US-202217842145-A
Country	US
Kind code	B2
Filing date	Jun 16, 2022
Priority date	Aug 16, 2021
Publication date	Jul 8, 2025
Grant date	Jul 8, 2025

Abstract

A dual-function supercapacitor carbon fiber composite stores electrical energy and functions, for example, as the body shell of electric vehicles (EVs). This is achieved with a vertically aligned graphene on carbon fiber electrode, upon which metal oxides were deposited to obtain ultra-high energy density anode and cathode. A high-strength multilayer carbon composite assembly is fabricated using an alternate layer patterning configuration of epoxy and polyacrylamide gel electrolyte. The energized composite delivers a high areal energy density of 0.31 mWh cm −2 at 0.3 mm thickness and showed a high tensile strength of 518 MPa, bending strength of 477 MPa, and impact strength 2666 J/m. To show application in EVs, a toy car body fabricated with energized composite operates using the energy stored inside the frame. Moreover, when integrated with a solar cell, this composite powered an IoT (internet of things) device, showing feasibility in communication satellites.

First claim

What is claimed is:

1. A method of making an energy storing carbon fiber reinforced polymer composite, the method comprising:
depositing cathode material patches at spaced locations on a first cross-weaved carbon fiber mat to form a first cathode, the deposited cathode material patches collectively having a first configuration;
depositing anode material patches at spaced locations on a second cross-weaved carbon fiber mat to form a first anode, the deposited anode material patches collectively having a second configuration that matches the first configuration; and
stacking the first and second cross-weaved carbon fiber mats so that the cathode material patches substantially align with the anode material patches with a first separator cross-weaved glass fiber mat positioned between the first and second cross-weaved carbon fiber mats,
wherein the first separator cross-weaved glass fiber mat includes electrolyte coating patches on both sides, the electrolyte coating patches having a third configuration that matches the first and second configurations; and
wherein the spaces between the cathode material patches, the anode material patches, and the electrolyte coating patches include a filler material.

2. The method of claim 1 further comprising:
depositing cathode material patches at spaced locations on a third cross-weaved carbon fiber mat to form a second cathode, the deposited cathode material patches collectively having a fourth configuration;
depositing anode material patches at spaced locations on a fourth cross-weaved carbon fiber mat to form a second anode, the deposited anode material patches collectively having a fifth configuration that matches the fourth configuration;
stacking the third and fourth cross-weaved carbon fiber mats so that the cathode material patches substantially align with the anode material patches with a second separator cross-weaved glass fiber mat positioned between the third and fourth cross-weaved carbon fiber mats;
stacking the stacked third and fourth cross-weaved carbon fiber mats and second separator cross-weaved glass fiber mat and the stacked first and second cross-weaved carbon fiber mats and first separator cross-weaved glass fiber mat with a first insulator cross-weaved glass fiber mat positioned between the second and third cross-weaved carbon fiber mats; and
electrically connecting the first and fourth cross-weaved carbon fiber mats in series,
wherein the second separator cross-weaved glass fiber mat includes electrolyte coating patches on both sides, the electrolyte coating patches having a sixth configuration that matches the fourth and fifth configurations; and
wherein the spaces between the cathode material patches, the anode material patches, and the electrolyte coating patches include a filler material.

3. The method of claim 2 , wherein the filler material comprises an epoxy resin.

4. The method of claim 3 , wherein the electrolyte coating patches comprise a PAM gel electrolyte.

5. The method of claim 2 , wherein the electrolyte coating patches comprise a PAM gel electrolyte.

6. The method of claim 1 , wherein the filler material comprises an epoxy resin.

7. The method of claim 6 , wherein the electrolyte coating patches comprise a PAM gel electrolyte.

8. An energy storing carbon fiber reinforced polymer composite comprising:
a first cathode including cathode material patches at spaced locations on a first cross-weaved carbon fiber mat, the deposited cathode material patches collectively having a first configuration;
a first anode including anode material patches at spaced locations on a second cross-weaved carbon fiber mat, the deposited anode material patches collectively having a second configuration that matches the first configuration; and
a first separator cross-weaved glass fiber mat positioned between the first and second cross-weaved carbon fiber mats,
wherein the first and second cross-weaved carbon fiber mats are stacked so that the cathode material patches substantially align with the anode material patches;
wherein the first separator cross-weaved glass fiber mat includes electrolyte coating patches on both sides, the electrolyte coating patches having a third configuration that matches the first and second configurations; and
wherein the spaces between the cathode material patches, the anode material patches, and the electrolyte coating patches include a filler material.

9. The composite of claim 8 further comprising:
a second cathode including cathode material patches at spaced locations on a third cross-weaved carbon fiber mat, the deposited cathode material patches collectively having a fourth configuration;
a second anode including anode material patches at spaced locations on a fourth cross-weaved carbon fiber mat, the deposited anode material patches collectively having a fifth configuration that matches the fourth configuration; and
a second separator cross-weaved glass fiber mat positioned between the third and fourth cross-weaved carbon fiber mats,
wherein the third and fourth cross-weaved carbon fiber mats are stacked so that the cathode material patches substantially align with the anode material patches;
wherein the stacked third and fourth cross-weaved carbon fiber mats and second separator cross-weaved glass fiber mat and the stacked first and second cross-weaved carbon fiber mats and first separator cross-weaved glass fiber mat are stacked with a first insulator cross-weaved glass fiber mat positioned between the second and third cross-weaved carbon fiber mats;
wherein the first and fourth cross-weaved carbon fiber mats are electrically connected in series;
wherein the second separator cross-weaved glass fiber mat includes electrolyte coating patches on both sides, the electrolyte coating patches having a sixth configuration that matches the fourth and fifth configurations; and
wherein the spaces between the cathode material patches, the anode material patches, and the electrolyte coating patches include a filler material.

10. The composite of claim 9 , wherein the filler material comprises an epoxy resin.

11. The composite of claim 10 , wherein the electrolyte coating patches comprise a PAM gel electrolyte.

12. The composite of claim 9 , wherein the electrolyte coating patches comprise a PAM gel electrolyte.

13. The composite of claim 8 , wherein the filler material comprises an epoxy resin.

14. The composite of claim 13 , wherein the electrolyte coating patches comprise a PAM gel electrolyte.

15. An energy storing device panel for a device comprising the carbon fiber reinforced polymer composite of claim 8 .

16. The energy storing device panel of claim 15 , wherein the device is an electric vehicle.

Assignees

• Univ Central Florida Res Found Inc

Inventors

• Thomas Jayan
• Pandey Deepak
• Kumar Kowsik Sambath

Classifications

• H01G11/70

  characterised by their structure · CPC title

• B62D29/043

  Superstructures (B62D25/161 takes precedence) · CPC title

• B60L50/40

  using propulsion power supplied by capacitors · CPC title

• B60Y2200/91

  Electric vehicles · CPC title

• H01G11/28

  arranged or disposed on a current collector; Layers or phases between electrodes and current collectors, e.g. adhesives · CPC title