5 th Progress Meeting INASCO (22 nd /23 rd May 2012)

© The Composites Centre, Imperial College London

5th Progress MeetingINASCO (22nd/23rd May 2012)

Emile S. Greenhalgh, Project Co-Ordinator

The Composites Centre, Imperial College, London


09:30 Coffee, Welcome and Introductions

09:45 Minutes of the Last Meeting

10:00 WP1: Management/Overview of Project and Deliverables (Imperial/SICOMP) 10:15 WP1: Status of project extension (Imperial/SICOMP)

10:30 WP2: Reinforcement Development (Nanocyl) - overall status and management 10:45 WP2: Partner Presentations (max 20 minutes each)

WP2 - Nanocyl, Swerea Sicomp, BAM, ETC

11:30 WP3: Multifunctional Resin Development (Imperial) - overall status and management

11:45 Partner Presentations (max 20 minutes each)WP3 - Imperial College London, Swerea Sicomp, Inasco, Chalmers, Umeco, BAM, ETC

12:30 WP8: Project Demonstration and Exploitation (Inasco)

13:00 Lunch

Agenda – 3rd Progress Meeting

Tuesday 22nd May (am)


14:00 WP6: Systems (SICOMP)14:15 Partner Presentations (max 20 minutes each)

WP6 - Swerea Sicomp, Imperial College London, Inasco, Volvo, ETC

15:15 WP7: Demonstrator Development (SICOMP)15:30 Partner Presentations (max 20 minutes each)

WP7 - Swerea Sicomp, Imperial College London, Inasco, Chalmers, Umeco, Nanocyl, BAM, Volvo, ETC

16:00 WP6/7 Discussion – Design of Wheel Well

17:00 End of day one

19:00 Common dinner in Athens


Tuesday 22nd May (pm)


09:15 Coffee and Welcome

09:30 WP4: Composite Manufacture (Umeco) - overall status and management

09:45 WP4: Discussion regarding weave issues and suggested mitigation (Imperial)

10:45 Partner Presentations (max 20 minutes each)WP4 – Umeco, Imperial College London, Inasco, Swerea SICOMP, Nanocyl

11:15 WP5: Composite Characterisation (BAM)11:30 Partner Presentations (max 20 minutes each)

WP5 – BAM, Imperial College London, Swerea Sicomp, INASCO, Chalmers, Umeco

12:30 AOB, Date of next meeting and close

13:00 Lunch

14:00 Optional tour of INASCO facilities


Wednesday 23rd May (am)


• Report on Progress in all Work Package, and compare with plan

• Progress the design of the wheel well (WP6/7)

• Resolve the issue of the influence of weave on electrical performance (WP4/5)


Objectives of Meeting

© The Composites Centre, Imperial College London6

Dinner is at 8pm and the location is Filistron restaurant.

Evening Plans

23, Apostolou Pavlou str. ThissionAthens11851

[email protected]+30 103422897

http://www.filistron.com/


Action On Outcome (Grey = complete)Action 2.12 Approach to David Porter at Oxford University to discuss GIM modelling in the context of structural power is still open. MRS happy to invite DP to Umeco to discuss this. ESG will contact him to arrange a visit.

ESG Complete – but awaiting response from David Porter

Action 3.10 Student projects are underway at Imperial. Please approach ESG if you are interested in being involved in these.

ICL/ALL Complete - Currently two UG projects underway looking at influence of curvature on structural power performance. One is making the U-section arms of the quadcopter from a baseline structural power material (PEGDGE + 10% IL). The other is making a model car body out of the material (Device B) in conjunction with Umeco and McLaren cars.

There are also two MSc projects which have just started. One is looking at alternative separator materials (in conjunction with McLaren) and the other is characterising the acoustic performance of our materials.

Actions from Last Meeting


Action On Outcome (Grey = complete)Action 4.3 ESG and LA have met to collate and formulate the amended document and formalize changes. ESG is currently revising the document, which will be issued to Mr Bird in February to apply for an extension.

ICL/ALL Complete - Document has been issued to the EU with request for an extension. Mr Bird has been positive about the outcome, but no further information yet.

Action 4.5 JS and PJ have developed a plan to determine the effect of moisture on the electrical properties, including its monitoring and methods to extract effects of moisture from all data established on resins and laminates to date and in the future. The document will be included with the minutes and partners should provide comments.

JS/PJ/ALL Complete – document issued

Action 4.10 ACG to send a specification of the screening tests at ACG for crashworthiness to MW. The specification has now been sent to ICL, who are developing it further and will issue a revised specification.

ESG Complete – Sang will elaborate on this

Action 4.11 BAM sorting out the revised sample code

MW Complete – BAM will elaborate on this

Actions from Last Meeting (Continued)


Action On Outcome (Grey = complete)Action 4.12 VE have sent ICL and NANOCYL information on the size of materials needed to make battery cells from CNT-coated and CAG-coated fabrics. NANOCYL and ICL will then send materials to VE and LA for tests in WP6. Also LA is to provide the MWCNT coated CF-fabric to KTH for coin cell tests. Sicomp and ETC have started to produce and test some smaller cells for evaluation of electrical properties, currently working with small cells using sheets of 40x40 mm. For the electrical properties of the materials in a battery this is sufficient. VE mentioned that 150x150mm cells have been suggested, and are currently focusing on improvement of the production method and the electrical performance of the battery cells. VE said ETC can use 40x40 mm for evaluating the materials from a battery perspective. If successful ETC can investigate the possibility to scale up for mechanical testing.

VE/LA/ESG/

MH



Action On Outcome (Grey = complete)Action 4.15 SICOMP/ACG to press forward on development of small-scale demonstrators to be used by the partners at future events such as JEC in April 2012. TC and QF/SC should discuss to move this forward quickly.

SC/TC/QF Complete – presented at JEC, Swedish national exhibition and Imperial Festival events.

Action 5.2 ESG/SN/MW to investigate scope for characterising the acoustic response of the STORAGE materials.

ESG/SN/MW Complete – MSc student will be working on this at ICL

Action 5.3 Regarding electrical connection of the laminates, there was discussion that read-across from lightning strike protection on conventional composites in aerospace applications could be utilized.

ESG/MM/MW Still being explored – there are some parallels but nature of the electrical loading is different.

Action 5.4 GW and PC will provide contacts in the aerospace industry who have knowledge of lightning strike protection in aircraft.

GW/PC Complete

Action 5.5 ESG will proceed with the extension application.

ESG Complete



Model Demonstrator• Radio controlled car built by SICOMP &

Umeco Two cell Device B laminates No batteries in car, battery in controller

charges roof laminate which lights LEDs Raised cutting/grinding issues –

laminates need to be made to size

• Demonstrated at a exhibitions, etc Umeco stand at JEC (Paris, 03/2012) Swedish Foundation for Strategic

Research’s (SSF) Materials Science Programme Conference - Stockholm (04/2012).

Video for ‘Fully-Charged’ show - http://www.youtube.com/watch?v=rMOxrDxq_do&list=PL971B96323746C745&index=8&feature=plcp

Imperial Festival (05/2012)


Action On Outcome (Grey = complete)Action 5.6 Formulate a small test plan to investigate the effect of moisture on electrical and mechanical properties of the laminates, as an extension of Action 4.5. It is suggested this will utilize Device B, and use in-plane shear testing. It is recognized that electrical testing after preparation for mechanical testing can be challenging, so perhaps the ‘traveller’ approach could be utilised here.

ESG/SN/NS/

JS

Plan for controlling moisture, using travellers, has been devised, but

Action 5.7 There is a need to consider metalized film for bagging of laminates to avoid moisture ingress. TC has information on the supply of such a metalized film which he will send to NS.

TC Complete – now being used

Action 5.8 There was discussion regarding cutting of these materials (which will need to be done dry), and GW suggested cryogenic cutting could be a good approach, and would send further details of this.

GW



Action On Outcome (Grey = complete)Action 5.9 During the meeting there was some discussion regarding weave style of the laminates, and it was identified that Devices A and B will need to be remade using 5HS fabric rather than plain weave material.

QF/SC Complete, but maybe revised. 5HS was confirmed. However, an unexpected problem has arisen which we will discuss during WP4.

Action 5.10 SICOMP will consider Device G and advise as to the approach to be taken towards manufacture for mechanical testing.

LA/TC Complete

Action 5.11 The test plan for the partners has been drawn up; this will be agreed with the appropriate partners. However, INASCO’s testing work is unclear; a short presentation was sent to MW by Tasia Gkika. The issues of what can be measured by INASCO will be established by discussion with Tasia.

ESG/MW/TG

Action 5.12 The temperature range and humidity range still needs to be established, and therefore a specification will be compiled.

ESG/LA/MW/

PS



Action On Outcome (Grey = complete)Action 5.13 MW will circulate the test plan and establish delivery dates for each stage so that the testing schedule can be finalized. Some fractography may be done at SICOMP and ICL.

MW Complete – a test plan has been issued (D5.1)

Action 5.14 For manufacturing plenum cover parts TC needs some MTM57 UD prepreg, any carbon fibre, about 10 cm width about 20 lm. Umeco will look into this.

QF/SC/TC Complete

Action 5.15 TC will consider the Gantt and work description to integrate the additional intermediate demonstrators, and will send this to ESG.

LA/TC

Action 5.16 MH will look into a cost analysis (if these costings can be compared in generic terms without revealing industrially sensitive process costs information.)

MH

Action 5.17 Scope for a student project on separators to complement STORAGE, and also scope to characterise the impact of different separator thicknesses/stiffnesses on the mechanical properties (both elastic and delamination).

ESG/SN Complete – student project currently underway to characterise this



Action On Outcome (Grey = complete)Action 5.18 PJ will ask TG for an explanation of what the presentation is showing.

PJ Complete

Action 5.19 QF will send TC some samples of veils, (typically a square foot).

QF

Action 5.20 TC has encountered issues with curing of his resins. He will discuss this with NS and SC.

TC/NS/SC Complete

Action 5.21 Regarding D4.1, QF to ask for information from partners to clarify what is required.

QF Report being issued to PC, and will reply with comments

Action 5.22 MM to speak to TG about their expertise in electrical connection to composite laminates.

MM



Dates for Future Meetings(Assuming Extension)

December 2012 Progress Meeting #6 – Imperial College London, UK

June 2013 Final Meeting – Volvo Car Corporation, Sweden,


Device Configurations

Supercaps 3 ply laminates (CF/GF/CF); Batteries 7 ply laminates (CF i/GF/CFii/GF/CFii/GF/CFi)

Device # Type Reinforce (i) Reinforce (ii) Insulator* MatrixMechanical Test

RegimeElectrical Test

Regime

A Baseline T300 fabric T300 fabric ACG Style 120 MTM57 Full None

BBaseline

Multifunctional

T300 fabric T300 fabric ACG Style 120 MTM57:IL:Li conc1 Reduced Reduced

C Supercap 1a T300 CNT T300 CNT ACG Style 120 MTM57:IL:Li

conc1 Full Full

D Supercap 1b T300 CNT T300 CNT ACG Style 120 MTM57:IL:Li

conc2 Reduced Reduced

E Supercap 2a

T300/AquaCyl 3+

T300/AquaCyl 3+ ACG Style 120 MTM57:IL:Li

conc1 Full Full

FBaseline

CNT Reinforced

T300 CNT T300 CNT ACG Style 120 MTM57 Reduced None

G Battery 1 T800 cloth (unsized) Metalised Film ACG Style 120 MTM57:IL:Li

conc1 Full Full

H Pseudo cap 1

MnO2 loaded CAG CAG ACG Style 120 MTM57:IL:Li

conc1 Reduced Reduced

I Capacitor 1 T300 fabric T300 fabric PET Film 1 MTM57 Full Full

J Capacitor 2 T300 fabric T300 fabric PET Film 2 MTM57 Reduced Reduced

K Hybrid 1 Best of above Best of above ACG Style 120 MTM57:IL:Li conc1 None Individual cells only


Laminates

Panel Details Dimensions Layup Mec Ele A B C D E F G H I J K

(i) Shear180mm x 180mm

[±CF/±GF]S X X X X X X X X X X X X

(ii) Compression180mm x 180mm

[CF4]S X X X X X X X X X X X

(iii)Fracture

Toughness / ILSS

180mm x 180mm

[CF/GF2/CF2/GF2/PTFE/CF2/GF2/CF2/GF2/CF] X X X X X X X


Laminates

Panels (i) and (v) [±CF/±GF]S

Panel (ii) [CF ]180 x 180 mm

4 S

Panel (iii) [CF/GF /CF /GF /PTFE/ ] 2 2 2 CF /GF /CF /GF /CF2 2 2 2


Mechanical Testing Regime

PropertiesTest

methodStandard

Specimen Size

PartnerTest

RegimeDevice # t Laminate # Stacking

Sequence

In-plane shear

modulus & strength

+/- 45° tensile test

DIN EN ISO 14129 - ASTM

D3039/D3039M

150mm x 25mm

ICL/BAM reduced/full A-J 1mm (4ply) (i) [±CF/±GF]S

compressive strength & modulus

compression test

(DIN EN ISO 14126) ICL

90mm x 10mm

ICL/BAM reduced/full A,C,E,G,I > 2 mm (ii) [CF4]S

ILSSbending test (short beam)

DIN EN ISO 14130 - ASTM

D2344/D2344M

25mm x 12mm

BAM/SICOMP

full A,C,E,G,I 3mm (iii)[CF/GF2/CF2/GF2/PTFE/CF2/GF2/CF2/

GF2/CF]

Interlaminar fracture

toughness energy

DCB test DIN EN 6033/6034180mm x

20mmSICOMP full A,C,E,G,I 3 mm (iii)

[CF/GF2/CF2/GF2/PTFE/CF2/GF2/CF2/

GF2/CF]

Tg

DMTA cantilever beam test

?10mm x 2mm

?Chalmers full A,C,E,G,I 0.4-0.6 mm (i) [±CF/±GF]S


Electrical Testing

• Supercapacitors: Charge-discharge experiments: Voltage - 0.1 V (most likely we will increase

voltage); Charge time 10 s (can be varied); Discharge time 10 s (can be varied). Cyclic voltammetry: sweep rates of 5 mV/s to 50 mV/s, window of −0.5 to 0.5 V. Electrochemical impedance; frequency range from 106 Hz to 10-3 Hz, sinusoidal

voltage amplitude 5 mV. Effect of moisture/temperature; DiAMon monitoring

• Batteries: Capacity and energy cycling, (Charge/Discharge) Self discharge Internal resistance - pulsed charge/discharge OCV characterisation, Life length

• Capacitors: effect of moisture and temperature DiAMon monitoring dielectric strength ? capacitance/ (specific energy) - 0.1-100Hz at 1V


Gantt1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Task Details J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J J A S O N D J F M A M J

1 10.2 Management1_1 10.2 Project Management

2 46.5 Reinforcement Development2_0 2.5 Work Package 2 Management2_1 25.5 Carbon fibre activation and grafting2_2 4.0 Separator layer development2_3 14.5 Anode (Metal Electrode) Development

3 71.5 Multifunctional Resin Development3_0 3.5 Work Package 3 Management3_1 34.5 Structural Electrolyte Development3_2 20.0 Structural Dielectic Development

4 41.0 Composite Manufacture4_0 1.5 Work Package 4 Management4_1 20.0 Composite Processing4_2 3.5 Capacitor Concepts4_3 3.5 Battery Concepts4_4 9.0 Supercapacitor Concepts4_5 3.5 Hybrid Capacitor Concepts

5 53.0 Composite Characterisation5_0 2.0 Work Package 5 Management5_1 14.5 Characterisation of electrical properties5_2 22.0 Characterisation of mechanical properties5_3 9.5 Crashworthiness5_4 5.0 Ranking of Devices

6 30.0 Systems6_0 1.0 Work Package 6 Management6_1 4.5 Concept Design6_2 14.5 Power Management and Connectivity6_3 8.0 Packaging and Integration6_4 1.0 Cost and Benefits Modelling and Analysis6_5 1.0 Ownership Issues

7 45.7 Demonstrator Development7_0 2.0 Work Package 7 Management7_1 6.0 Demonstrator Design7_2 15.0 Demonstrator Manufacture7_3 14.0 Demonstrator Testing and Evaluation7_4 8.7 Demonstrator Assessment

8 5.0 Dissemination and Exploitation8_1 5.0 Project Dissemination and Exploitation

20132010 2011 2012


Deliverables Completed to date# Deliverable name WP Lead Original New Date Motivation

1.1Project Management plan, Risk

Register and Quality PlanWP1 ICL Mar-10 Mar-10 Complete

2.1 Delivery of optimised separator layer WP2.2 NCYL Sep-10 Dec-10 Complete

3.1Delivery of dielectric matrix materials

for capacitor applicationsWP3.2 SICOMP Sep-10 Dec-10 Complete

8.1 Internal collaborative website set-up WP8.1 ICL Mar-10 Dec-10 Complete

2.2Report on the mechanical

characterisation of the activated and CNT grafted carbon-fibres

WP2.1 NCYL Nov-10 Mar-11 Complete

3.2

Report on the development and characterisation of matrix materials

for structural supercapacitor applications

WP3.1 ICL Feb-11 Mar-11 Complete

4.2Completed fabrication of composite

capacitor devicesWP4.2 ACG Mar-11 Mar-11 Complete

6.1Report on the cost/benefits analysis of structural power source materials

WP6.4 SICOMP Apr-11 May-11 Complete

2.3Report on SICOMP connector

developmentWP2.3 NCYL Dec-10 Jun-11 Complete

6.2Report on the ownership issues associated with structural power

source materialsWP6.5 SICOMP Jul-11 Jul-11 Complete

1.2 1-18 Month Report WP1 ICL Jun-11 Aug-11 Complete5.1 Testing Plan WP5 BAM Feb-12 New Deliverable


Deliverables due soon# Deliverable name WP Lead Original New Date Motivation

4.1

Report on the generic fabrication issues regarding fabrication of

composite structural devices and recommended processing

guidelines

WP4.1 ACG Mar-11 Feb-12About to be issued - currently with

ESG

2.4

Report on the development and scale-up of activated and CNT

grafted carbon-fibres for structural power applications at NCYL

WP2.2 NCYL May-11 Feb-12 Knock-on delays with D2.2

3.3

Report on the development and characterisation of matrix materials for structural hybrid capacitor and

battery applications

WP3.1 SICOMP Jun-11 Feb-12

Research will focus on tasks associated with hybrids once supercapacitor and battery

technologies have been frozen.

2.5Report on anode layer development

and characterisationWP2.3 NCYL Dec-10 Mar-12

Covering SICOMP metalized film and ICL CAG configurations


supercapacitor devicesWP4.4 ACG May-11 Mar-12

Delays in constituent development have had a knock-on effect on the

supercapacitor fabrication.


batteries devicesWP4.3 ACG May-11 Jun-12

Delays in constituent development have had a knock-on effect on

battery fabrication.

6.4Report on the connectivity and packaging issues of structural

power source materialsWP6.2 SICOMP Dec-11 Jun-12

Delay associated with delays in other WPs regarding

characterisation of devices


Deliverables due before next meeting# Deliverable name WP Lead Original New Date Motivation

5.2Report on the electrical properties

of structural power source materialsWP5.1 BAM Oct-11 Aug-12

Knock on from delays in constituent development

5.3Report on the mechanical

properties of structural power source materials

WP5.2 BAM Nov-11 Aug-12Knock on from delays in constituent development

6.3Report on the conceptual design of structural power source materials

WP6.3 SICOMP Oct-11 Aug-12Delay associated with delays in

other WPs regarding characterisation of devices

5.5Report on the ranking of the

structural power source devicesWP5.4 BAM Feb-12 Sep-12

Knock on from delays in constituent development

3.4Report on improved performance of multifunctional resins for structural

supercapacitor applicationsWP3.1 ICL Jun-11 Sep-12

Change in research focus. The approach is to move effort to

further develop the resin formulation chosen in D3.2 to

improve its mechanical properties.

6.5Chosen configuration for design of

demonstratorWP6.1 SICOMP Dec-11 Oct-12

Knock on associated with delay in earlier WPs

7.1Design of the demonstrators

completeWP7.1 SICOMP Mar-12 Dec-12

Knock on associated with delay in earlier WPs


hybrid capacitor devicesWP4.5 ACG Aug-11 Dec-12

Shifting of hybrid development has led to a shift in fabrication (and characterisation) of final

devices.

5.4

Report on the crashworthiness of the structural power source devices

and methodology to mitigate thermal issues

WP5.3 ACG Dec-11 Dec-12Knock on from delays in constituent development

Documents

5 th Progress Meeting INASCO (22 nd /23 rd May 2012)