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Smart lightweight functionalized materials for Housing of Batteries-SmartHouB

Abstract

SmartHouB will develop a novel functional hybrid laminate material system combining printed electronics with a lightweight structural composite and a metal layer. Laminate sheets are intended to be processed into structural shell-type parts by forming processes, and parts can subsequently be joined by adhesive bonding, cinching or friction stir welding-the latter will be further developed within the project. The printed electronics layer will use different forms of carbon-derived nanomaterials to achieve enhancing sensing ability, and to allow for interconnects that can withstand forming processes. These nanomaterials will have tightly controlled properties yet can be produced at low cost, enabling widespread use in consumer applications. The structural composite layer will use continuous basalt fibers as reinforcements in a thermoplastic matrix, enabling components that are strong, light, and fully recyclable. A thin aluminium layer adds ductility (for the forming processes) and enhanced stability at elevated temperatures. We will demonstrate the use of the functional hybrid laminate as a material for battery pack housings (such as used in electric bikes, cars and other mobile products). By embedding a matrix of sensors in the housing, it will be possible to estimate the internal temperatures of the battery cells without the complexity associated with discrete sensors on/in the cells-enabling some 5% cost saving on the battery pack and therefore a high economic and environmental impact. (AU)

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