Di Mauro, Gennaro (2024) A multidisciplinary approach for Structural Batteries integration in Aeronautical Applications. [Tesi di dottorato]

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Abstract

This dissertation aims to capture the inherently interdisciplinary nature of Structural Batteries. This novel technology, deeply investigated in the research context, represents a plausible solution for improving aircraft electric energy-storing efficiency, thus enabling electrification towards environmental friendliness of air transport. Structural Batteries are multifunctional components, manufactured similarly to composite materials already used on many aircraft, and capable of replacing stress-supporting parts while also serving as energy-storing components. Along with the definition of the State of the Art on the topic, information about structural batteries working principles and configurations is provided. The manufacturing of a Structural Battery demonstrator is addressed, detailing its configuration, the choice of components and the applied chemical treatments. A focus on the Solid Polymer Electrolyte layers is provided. Different formulations have been manufactured and preliminarily characterized by means of chemical-physical and mechanical tests. Efforts have been dedicated to the cathode functionalization, performed with a specific lithium salt. Therefore, accounting that the electrical performance of the structural battery depends on various factors such as the level of adhesion of the salt to the carbonaceous substrate as well as the content of the bonded salt to the substrate, various physio-chemical procedures capable of fixing an adequate amount of lithium salt on the carbonaceous base fabric have been explored. The effectiveness of the adopted procedure has been monitored with specific surface characterization techniques, such as morphological surveys. Furthermore, along with the description of the applied assembling procedure, testing results are provided. Structural battery specimens, made in the form of panels, have been preliminary validated both structurally and electrically. Along with the manufacturing activities, the importance of developing Structural Batteries for aeronautic applications is pointed out. Specifically, an evaluation of the potential benefits the Structural Batteries have on the fuel burn of a hybrid-electric commuter aircraft is delivered. Therefore, the best hybridization factors determining the energy requirements for the typical mission of the commuter aircraft are defined. Finally, drawbacks related with the integration of Structural Batteries in aerostructures are drawn, mainly focused on the certification point of view, for making them airworthy. A viable route for defining safety criteria for Structural Batteries is provided, by acknowledging their dual functionality and thus leveraging relevant regulations already available for conventional lithium-ion batteries and composite structures, while assuming valid the performance-based approach advocated by certification entities. In this context, the development of physics-based safety design tools, tailored specifically for battery structures, is identified as a crucial contribution to ensuring the safe and successful integration of structural batteries within the aeronautical field.

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