Experimental study on post-impact loading of composite sandwich-structured batteries

With the growing trends of electrification in the aerospace and automotive industries, the integration of lithium-ion batteries into composite materials offers a promising solution for extending range and reducing dependence on petroleum-based energy sources. This study investigates the mechanical behavior and electrochemical performance of composite sandwich-structured batteries, where batteries are embedded within foam sandwich panels, under varying levels of impact energy. Two sizes of foam sandwich-structured batteries were fabricated using Vacuum Assisted Resin Transfer Molding (VARTM) and subjected to impact tests. Digital Image Correlation (DIC) was employed to observe the strain fields during Compression After Impact (CAI) and Bending After Impact (BAI) loading, while X-ray Computed Tomography (CT) was used to examine delamination at the battery-core interface and internal damage within the composite. The results show that foam sandwich-structured batteries exhibit excellent impact resistance and maintain electrochemical performance post-impact. Innovatively, this study combines the assessment of both mechanical and electrochemical performance to reveal the post-impact residual performance of composite sandwich-structured batteries, with a particular focus on the interactions between the foam core, carbon fiber faces, and embedded battery. This research provides valuable theoretical and experimental insights for the design of integrated electrochemical energy storage systems for future applications.