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BAE turns Le Mans race car’s carbon fiber body into a battery

By | February 13, 2012, 5:03 PM PST

Body Boost: Engineers will mold a battery right into the carbon fiber body of this Lola-Drayson Le Mans prototype.

British defense firm BAE Systems has developed a technology that turns carbon fiber and other materials into a battery, allowing car bodies to provide power in place of weighty battery packs.

BAE said in a press release that its “structural battery” currently works with carbon fiber and glass reinforced plastics, and that it will develop it for a wide range of lightweight fabrics leading to applications “from tents with their own power supply to making electric blankets a literal reality.”

The company is testing the technology in the Lola-Drayson B12/69EV Le Mans car, introduced at the 2012 Low Carbon Racing Conference last month in Birmingham, England by British companies Lola Group and Drayson Racing with the aim of making it the world’s fastest electric race vehicle.

Lola-Drayson will use the technology to power “some of the on-board electronic system,” according to the press release.

BAE has already demonstrated the technology in a drone - a high tech micro unmanned air vehicle as BAE calls it -  and in a flashlight. It developed it to lighten the load of soldier’s backpacks, which can weigh up to 176 pounds when full of electrical gear.

The technology “merges battery chemistries into composite materials that can be molded into complex 3D shapes and so form the structure of the device itself,” the press release states. It uses nickel - common in military gear for its longevity and durability. Future designs will include lithium ion and lithium polymer technologies which are common in consumer gadgets.

“The structural batteries store the electrical energy within the physical structure of a device and thus helping to reduce or eliminate the need for traditional batteries, which create weight and bulk, as well as the burden and cost of carrying spares,” BAE said.

“Structural batteries can be used in virtually anything that requires electricity from small gadgets to entire vehicles,” added Alex Parfitt, BAE capability technology leader for materials. “It can not only support our soldiers on the frontline, but also revolutionize technology in the consumer market by allowing more efficient, elegant and lighter designs.”

According to the BBC, BAE is working to increase the structural batteries’ power density - the amount of energy they store per weight - which is currently very low at about a third of electric car batteries and a tenth of the lithium batteries in consumer devices.

Drayson, part of the race team testing the technology, is also testing an on-the-go wireless charging system from Qualcomm, which recently acquired the technology via its acquisition of British/New Zealand firm HaloIPT.

Before the BAE technology catches on in the mass market, it will also have to overcome cost barriers.

In its press release BAE called structural batteries, ”The most radical method of storing electricity since the invention of batteries over 200 years ago,” and said they “may lead to a redesign of all electrical technology.” British understatement ain’t what it used to be.

Image: Screen grab of Lola-Drayson B12/69EV from Drayson Racing web video.

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Mark Halper

About Mark Halper

Mark Halper is a contributing editor for SmartPlanet.

Mark Halper

Mark Halper

Contributing Editor

Mark Halper has written for TIME, Fortune, Financial Times, the UK's Independent on Sunday, Forbes, New York Times, Wired, Variety and The Guardian. He is based in Bristol, U.K.

Follow him on Twitter.

Mark Halper

Mark Halper

Mark has no financial holdings in the companies he writes about. He occasionally travels at the expense of companies or their press relations agencies in order to report on a company or industry event related to it; Mark will prominently disclose this information when appropriate. This relationship will have no influence on his coverage. Companies he covers do not get to review columns in advance, or select or reject topics.

He writes for SmartPlanet and is not an employee of CBS.

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Batteries wear out
If the battery is integrated into the chassis of the vehicle what happens when the battery is beyond its useful life? Do you just have to throw the whole thing out?
Posted by riverat1
14th Feb 2012
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Exciting Development!
Sounds like an exciting development ??? thanks for sharing, Mark Halper! This is yet another great application of using carbon fiber in vehicles to reduce weight. And because this material is also known for its energy-absorbing strength, drivers who take advantage of this technology can benefit from both increased safety and improved efficiency.

For more on lightweight car parts, visit: http://www.facebook.com/plasticcar and www.plastics-car.com

Rob Krebs, Market Innovations, American Chemistry Council
Posted by RobKrebs
22nd Feb 2012
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