GB2499455A

GB2499455A - Fibre reinforced capacitor

Info

Publication number: GB2499455A
Application number: GB1202856.9A
Authority: GB
Inventors: Jon Otegui Van Leeuw
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-02-17
Filing date: 2012-02-17
Publication date: 2013-08-21
Also published as: GB201202856D0

Abstract

A structural laminate material comprising a laminate which comprises multiple metallic film layers (1.2) which are laminated together with optional reinforcing fibre layers (1.6) embedded in an adhesive (1.3), thereby forming a capacitor. The laminate material offers the ability to store charge in the double metallic layers by using one of the metallic films as the positive pole (1.4) and the other metallic film as the negative pole (1.5), whilst the fibres add strength to the structure. The adhesive serves as an insulator due to its polymeric properties. The adhesive used to laminate the metallic film layers together may be a thermosetting epoxy resin, and the fibres may be glass, carbon, nylon, cellulose.

Description

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Title:

Energy storage capable structural laminate material Technical fields:

Aircraft structures, materials science, composites engineering, manufacturing engineering

Prior art:

Prior art elements incorporate the use of the same element for material for both energy storage and damping (US 3704877), which concerns the use of a spring made of composite materials to performs these two function simultaneously. Other energy storage prior art elements include energy storage methods by the means of a flywheel device (US 5452625).There are material concept design developed for thermal energy storage applications like that shown on (US 4572864). There are other energy storage devices such as composite structures having impervious core for use in an energy storage device (US 2005/0208382 Al). Another published concept includes the use of various material layers layered on each other long wires, hence forming metalized wires which offer electrochemical energy storage capability (US 2010/0261071 Al).

There is an energy storage device concept which is especially designed for energy storage using the capacitance principle. That concept includes a super capacitor having its first and second electrodes forming a composite wire, which hence means that a set of wires forms an energy storage device. This can be seen on the publication (US 2010/0259866 Al).

It can be seen that there is evidence that pervious energy concepts concerning energy storage devices and materials has been performed according to the prior art. However, none of the

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prior art elements incorporate the invention concerned in the concept concerned in this application.

Evidence can be seen that the new material concerned will function perfectly on any structural object, as GLARE (GLAss Aluminium Reinforced Epoxy) composite materials are widely used, most notably in aerospace structures, which is the main embodiment of the new composite laminate in question for this application. However, metallic composite laminates could be used as energy storage capacitor devices by following similar architectures to that of GLARE.

However, none of these prior art and publication elements offer this invention's innovation: to use a metallic laminate composite structure of an object for capacitance energy storage by using the metallic layers as the conductors (positive and negative) and the epoxy resin layers as the insulator between the two metallic foils.

Description of the invention:

The present invention comprises of a composite laminate material which is designed to offer structural strength, low fatigue and low density, while at the same time offering energy storage capability, hence making it a multifunctional material. The present application also includes the design and manufacturing features of the new material.

Material structural design outline:

The present invention comprises a metallic composite laminate, which is comprised of double metallic foil (or film) layers [1.2] (two metallic film layers laminated together) which are laminated together with insulating adhesive [1.3]. The metallic film layers are each fully covered with insulating adhesive [1.3], and are laminated between layers of thermoset resin

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(e.g. epoxy resin) [1.1], in which the reinforcement fibres [1.6] may be imbedded. The two metallic foils comprised in each double metallic layer forms an electrical energy storage capacitor be using the first layer as the positive pole [1.4] and the second layer as the negative pole [1.5]. The thermoset resin which laminate the materials multiple layers altogether prevents any flow of electrons form the metallic films to any other layers of the laminate due to the insulating properties of the adhesive [1.3]. Each metallic layer should be preferably a double metallic film layer, but other configurations such as triple metallic layers, quadruple metallic layers or greater, can also be optionally used in the material's design architecture.

The adhesive [1.3] is preferably a thermoset resin and more preferably epoxy resin, which also serves as an insulator as a consequence of the insulating properties of the polymer resin. The adhesive [1.3] acts as a multifunctional material, hence acting as an adhesive and as an insulator simultaneously.

The metallic layers [1.2] can be made of any metal or alloy, while the fibres [1.6] can be of any type (e.g. glass, carbon, nylon, cellulose, or any metal or alloy). As a result of the new material's architecture (Figure 1), the material can be used not only as a structural material, but also as an electrical energy storage device, by taking profit of the materials used in the material architecture concerned in order to convert the material into a capacitor. Hence, the result is a material which could be used for any structural application, which offers both electrical energy storage and the required structural properties simultaneously.

In order to form an electrical energy storage device by using the new composite laminate, at least 2 metallic foil layers are need [1.2], which should be preferably laminated with epoxy resin [1.3] in order to protect the metallic film layers from corrosion from the outer environment, as well as to avoid any contact between the metallic films and any other

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electrical conducting material, such as the reinforcement fibres. Additionally, before laying the fibres of each of the metallic foil layers, the layer of epoxy resin coating the outer layers of the metallic films, preferably required to be laid over the metallic film [1.3] and to be procured prior of inserting the fibre layers. This should be done in order to guarantee the avoidance of any contacts between the fibres and the metallic film layers, as any contact between the fibres and the metallic layers may result in short-circuits when charge is being stored in the metallic film layers.

At least two metallic foil layers [1.2] are needed in order to convert the metallic composite laminate into an energy storage capacitor. This is because two conductors are needed, which include a positive pole [1.4] and a negative pole [1.5]. Hence, the insulating properties of the epoxy resin, combined with the conductive properties of the 2 metallic layers, create a multifunctional composite laminate due to the conductive properties of each of its laminated materials.

Hence, a double metallic foil layer creates a capacitor capable structure. In order to generate the required material thickness, the laminate is to be successively laminated in various iterations with more metallic film layers until obtaining the required material thickness.

Each of the two metallic layers featured in each double layer of the metallic composite laminate features a connector which can be used to couple it to a battery, and hence create circuit in order to charge the material. Material charging can be done on any object built with the laminate concerned, and on any medium. In the case of aerospace vehicles, charging would be done preferably on the ground, so that the aerospace vehicle concerned would need less fuel energy due to the fact that part of the required energy would be supplied by the structure itself, hence minimising fuel consumption, and hence improving efficiency,

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decreasing C02 emissions and saving energy. However, this principle is applicable to any static or moving object which requires an energy source, or electrical energy storage.

In a material which offers a high electrical conductivity in order to maximise the capacitance of the material per unit of volume, hence maximising the number of metallic layers per unit of distance along the material's cross-section, and hence maximising the material's capacitance capability. The metallic film layers are required to be extremely thin and offer good electrical conductivity.

The material can be laminated in various structural configurations according to the structural requirements of the application in question.

A set of metallic foil layers can be laminated together until reaching the required material thickness [Figure 9].

Also, a set of material layers can be laminated together by using the same material double layer and laminating it together in various successive iterations while constantly using the same 2 long metallic foil layers embedded between layers of adhesive and reinforced with fibres [Figure 10].

Furthermore, a set of 2 metallic foil layers embedded in epoxy resin and fibre layers can be laminated together successively using the same double layer until obtaining the required material thickness, but by laminating the same double layer together by winding the metallic layers around a barrel, hence resulting in a monolithic laminated barrel [Figure 13]. This barrel lamination method can be used to form a monolithic structure with the same capacitor layer, hence making a capacitor capable structure. This technique can be used for aerospace

fuselage applications, thanks to a lower number of composites together with energy storage capability in the structure.

Each figure represents the various material design possibilities, which hence means that each can be described in more detail.

The layers can be configured in the configurations shown on Figure 1, 2, 3 and 4. This means that the metallic layers [[1.2], [2.2], [3.2], [4.2]] are embedded between the reinforcement layers, which consist of the reinforcement fibres [[1.6], [2.6], [3.6], [4.6]] embedded in the embedment adhesive layers [[1.1], [2.1], [3.1], [4.1]]. Each metallic layer is pre-coated with adhesive prior of being laid over the adhesive-coated fibre layers, whish hence means that the metallic layers are adhesive-coated with adhesive layers [[1.3], [2.3], [3.3], [4.3]], which are hence used to laminate metallic layers together.

The adhesive-coated metallic layers should be composed of at least two metallic foils (at least a double metallic foil layer) [[1.2], [2.2], [3.2], [4.2]], as in order to use the metallic foil layers as capacitors, at least two metallic foils are needed per layer (one for the positive pole and the other on for the negative pole).

The metallic foil layers can be composed of more than two adhesive-coated foils. The metallic layers can be double layers (Figure 1), triple layers (Figures 2 and 3), quadruple layers (Figure 4), or greater according to the composite architecture required.

Metallic fibre-reinforced composite laminates featuring double metallic foil layers use one foil as the as positive pole [1.4] and the other foil as the negative pole [1.5].

Metallic fibre-reinforced composite laminates featuring triple metallic foil layers can use the two outer foils of the triple metallic layer as positive poles [2.4] and the inner layer as the

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negative pole [2.5]. The two outer foils of each metallic layer can also be used as the negative pole [3.4] and the inner foil as the positive pole [3.5]. These configurations hence cerate capacitor-capable metallic composite.

In the case of metallic fibre-reinforced composites featuring quadruple adhesive-coated [4.3] metallic foil layers [4.1], each quadruple metallic layer can be used to act as a double capacitors, as the two positive pole foils [4.4] are separated by the two negative pole foils [4.5].

Another material architecture that can be carted in order to maximise the capacitance of a composite laminate can be that shown on Figure 5. In that case, the metallic layers [5.4] are adhesive-coated with adhesive layers [5.3] in order to adhesive lamination between the metallic layers [5.4] and to insulated each layer form the other. This material architecture consist of the positive pole layers [5.1] embedded between the negative pole layers [5.2], hence creating a composite laminate which offers maximised capacitance per unit of volume.

Another possible architecture would be incorporate the usage of the reinforcement fibres additionally to the metallic foil layers as negative and positive poles in order to be used for capacitance purposes (Figure 6 and 7). This means that the positive pole fibres are laid between the negative pole fibre and vice-versa, which hence creates a capacitor in the reinforcement layers as well.

This technology however can also be used for fibre reinforced composites without foil layers being incorporated in the matrix.

For this type of material, the conductive properties of the fibres are used in order to create a capacitor embedded in the reinforcement fibre/adhesive layers. Therefore, in this material's

case, the fibres to use would be conductive fibres, and most preferably metallic fibres, such as copper, aluminium, tin, nylon or iron fibres.

The configuration of this material comprises the metallic layers [[6.2], [7.2]] being embedded between adhesives layers [[6.3], [7.3]]. The layers of adhesive-coated metallic foils are embedded between the reinforcement layers, which comprise the reinforcement fibres [[6.6], [7.6]] embedded inside the embedment adhesive [[6.1], [7.1]]. The adhesive-coated metallic foil layers can be either double, triple, quadruple, or larger, and comprise the positive pole foils [[6.4], [7.4]] along the negative pole foils [[6.5], [7.5]] and vice-versa.

In the material architecture concerned, the positive pole fibres [6.7] can be aligned in parallel to the negative pole metallic foils [6.5], and vice-versa, which means that the negative pole fibres [6.8] can be aligned in parallel to the positive pole metallic foils [6.4]. This configuration hence also creates a capacitor between the metallic foils and the conductive reinforcement fibres of the materiel. As a result, the negative pole fibres [6.8] and the positive pole fibres [6.7] are aligned in parallel to the metallic foils [6.2] and following the metallic foils' alignment direction.

Another configuration would comprise each set of conductive reinforcement featuring a different polarity (one fibre after the other) along a direction parallel to the metallic foils (Figure 7), hence taking less profit of the proximity to the metallic foils, but still creating capacitance in between the opposite pole fibres and in between the opposite pole fibres and metallic foils. This means that the positive pole fibres [7.7] and the negative pole fibres [7.8] follow each other and are aligned in parallel to the metallic foil layers [7.2], without matter if they are positively poled [7.4] or negatively poled [7.5],

The main general architecture of the new capacitor-capable energy storage material can be seen on Figure 8, which consist of the positive pole metallic foils [8.2] being laminated with the negative pole metallic foils [8.3] by the means of an insulating adhesive layer [8.1]. The metallic foil layers are each fully coated on both sides with an insulating adhesive layer [8.1]. The adhesive-coated metallic layers are embedded between the reinforcement layers [8.4] of the composite material.

The reinforcement layers [8.4] can be structural reinforcements (e.g. honeycomb), fibre reinforcements (e.g. glass, carbon, copper, tin, aluminium, iron, nylon), particle reinforcements (e.g. concrete), or sandwich reinforcements (e.g. sheet and foil layers). Other possible reinforcements [8.4] can include foam materials.

The fibre reinforcements of the material can also be nanotube fibres, such as carbon nanotube. This would hence give higher strength and lower weight to the material, while at the same time offering capacitance. The reinforcement nanotube fibres can be used as negative and positive poles for capacitance proposes thanks to their electrical conductive properties, provided that these are made of electrical conductors (e.g. carbon, copper, tin, aluminium). However, the reinforcement nanotube fibres can be made of any material (e.g. glass), independently of the electrical conduction properties of the material.

The sheet and foil layers can be polymer layers, metal layers, or any material in the form of sheet.

The adhesive used in the new material should be preferably a thermoset resin, and more preferably epoxy resin (both for the metallic layers' adhesive coating and fibre embedment adhesive layers).

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The conductive material (conductor) used for the conductive foil layers should be preferably metals or alloys, and most probably copper, aluminium, tin, or copper, aluminium and tin alloys. Additionally, the conductive material layers (preferably metallic) should be preferably in the form of sheet, and most preferably in the form of foil or film, as the thinner re the conductive layers, the greater the charge stored per unit of volume in the material.

Each set of positive pole and negative pole conductor foil layers (2 layers per set) can optionally feature electrical charging connectors in order to be able to connect them to a source of electromotive force in order to charge the conductive fibres with charge. If the number of conductor layers is minimised (e.g. the configuration shown on Figure 10), a much lower number of connectors will be needed. If the configuration shown on Figure 10 features conductor layers made of only two foils (on positive pole and the other negative pole), only two connectors will be needed (one per foil).

Therefore, the lower the number of foils in the material, the lower the number of charging connectors needed.

In the composite material's design, the number of fibre layers can also be minimised. This can be done by using a composite design in which long single fibre layers [28.1] and folding them over the previous fibre layers [28.3] continuously until reaching the required material width (Figure 28), which means that the fibre layers [28.3] are laid in a direction parallel to the material's plain surface (along the material's plain surface) [28.4], In this process, these are laid over the first layer of adhesive (not cured or optionally pre-cured) [28.2], prior of being fully coated with the adhesive embedment layer [28.5], hence obtaining a fibre-reinforced composite material in which the number of fibres [28.3] which are present across

-lithe material's thickness is equivalent to the number of fibres present along the whole length of the composite structure concerned.

Composite materials which comprise adhesive and conductive fibres (which are hence also used for capacitance purposes) can optionally feature electrical charging connectors in order to charge the capacitor capable fibres, so, in other words, to connect each positive and negative pole set of fibres (2 fibres per set) to a source of electromotive force in order to charge the conductive fibres with charge.

If the configuration shown on Figure 28 features fibre layers made of only two fibres (on positive pole and the other negative pole), only two connectors will be needed (one per fibre).

Therefore, the lower the number of fibres in the material, the lower the number of charging connectors needed.

Material layer cross-sectional design layouts, material layer configurations, and outline of manufacturing processes:

The new multifunctional composite laminate should be manufacturing in such a way that any contact between the fibres and the metallic film layers is avoided.

So, two metallic foil layers [24.1] are initially each coated with adhesive [24.2] and laminated together, hence creating a double metallic layer. Then, the double layer is evenly coated with adhesive on both sides [24.4], which is then pre-cured [24.5], hence creating an adhesive-coated double metallic layer laminate [24.6]. After pre-curing the double metallic layers, the reinforcement fibres [24.7] are to be laid on the pre-cured layer of epoxy resin on both sides of the epoxy coated double metallic layer, so that the material is reinforced with fibres. Therefore, the fibres can then be covered with the adhesive embedment layer [24.8]. Then,

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the process is repeated various times successively until achieving the required material thickness. Finally, the newly formed metallic composite laminate matrix is to be totally cured in an autoclave [24.9], hence resulting in the new multifunctional composite laminate.

Reinforcement fibre layers [24.7] can be both particle reinforced and fibre reinforced. However, the most suitable reinforcements to use are linear fibre reinforced layers.

The reinforcement fibre layers can include woven fibres or non-woven fibres.

The whole manufacturing process is shown on Figure 24.

Layer [24.7] can however be all types of reinforcements (not only fibres).

Structural laminates can also be made by this method, but however, no embedment adhesive layer will be needed after laying the reinforcement layer, as in the case of structural composites, the reinforcement material will be cured with the metallic layer's pre-cured adhesive layer. Hence, in the case of structural composites, operation [24.8] will not be needed after laying the reinforcement layer [25.7]. This means that in the case of structural composite manufacturing, the manufacturing process will be that shown on Figure 25. Explaining in more detail, a metallic foil [25.1] is coated with adhesive [25.2], resulting in an adhesive-coated metallic foil [25.3]. Then, the adhesive coated metallic layer is coated with another metallic layer [25.1], The double metallic layer laminate is then adhesive-coated on both sides [25.4] and then pre-cured in an autoclave [25.5], hence resulting in a metallic laminate coated with pre-cured adhesive [25.6]. Then, the metallic laminate is to be covered with the structural reinforcement layer [25.7] on both sides. So, the previously explained process is repeated successively until achieving the required material thickness. When the

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required thickness is achieved, the material is fully cured in an autoclave [25.8], hence resulting in a metallic energy storage-capable structural laminate [25.9].

In the case of a metallic energy storage-capable composite laminate made up of only metallic foil layers laminated together with adhesive layers in between (Figure 5), the material can be made by laminating the metallic layers together as shown on Figure 26. Another option is to make a composite laminate based only on the metallic composite layers, which will hence not need any embedment adhesive filling operation [24.8] and any other material reinforcement [25.7],

Explaining in more detail, a metallic foil [26.1] is coated with adhesive [26.2], resulting in an adhesive-coated metallic foil [26.3]. Then, the adhesive coated metallic layer is coated with another metallic layer [26.1], The double metallic layer laminate is then adhesive-coated on both sides [26.4] and then pre-cured in an autoclave [26.5], hence resulting in a metallic laminate coated with pre-cured adhesive [26.6]. Then, the metallic laminate is to be covered with another metallic laminate coated with pre-cured adhesive [26.6] on both sides. So, the previously explained process is repeated successively until achieving the required material thickness. When the required thickness is achieved, the material is fully cured in an autoclave [26.7], hence resulting in a metallic energy storage-capable metallic laminate [26.8].

In the case of the process shown on Figures 24, 25 and 26, the process is to be repeated systematically until obtaining a material structure with a least 2 metallic foil layers (at least one double metallic foil layer), until obtaining the required material thickness.

The energy storage laminate material can be made by laminating the layers in various methods in order to minimise the number of components needed to obtain the required material thickness.

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The most simple method is lying the adhesive-coated metallic layers [[9.3], [14.3], [19.3]], one after the other successively until creating a multiple layer laminated material [[9.1], [14.1], [19.1]]. The metallic layers are laid over a mandrel [[9.2], [14.2], [19.2]] in order to obtain the composite structure's required shape. Then, the mandrel with the layers still laid over it is being placed on an autoclave in order to cure the adhesive before taking the composite structure out of the mandrel's surface.

The process shown on Figure 9 can also be used for the laying of the fibres. In this case, the fibres [[9.3], [14.3], [19.3]] are laid over the mandrel as shown on Figure 9.

Structural composites can also be made by inserting the reinforcement layers [14.5] between the metallic layers [14.3], hence creating a metallic composite with a structural reinforcement [14.4] in between the laminated layers [14.1]. The mandrel [14.2] gives the required shape to the composite structure.

Fibre- reinforced composites can also be made by the process shown on Figure 19. In this case, the adhesive [19.6] is laid between the metallic layers [19.3] and the fibre layers [19.5], hence creating a fibre reinforced composite, which is composed of reinforcement of fibre layers embedded in adhesive [19.4] embedded between layers of metallic material [19.1]. The mandrel [19.2] gives the required shape to the composite structure.

Another method is laying successively the same adhesive-coated metallic foil layer [[10.3], [15.3], [20.3]] over and back over again successively until obtaining the required thickness of the multilayer metallic composite material, which results to be formed of only one layer [[10.1], [15.1], [20.1]]. The layers are laid over a mandrel [[10.2], [15.2], [20.2]] to give the required shape to the material. The structure created is a monolithic laminate structure based on only one layer (one component), hence resulting in only one connector needed to charge

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the energy-storage capable structure, and improved structural integrity. Then, the mandrel with the layers still laid over it is being placed on an autoclave in order to cure the adhesive before taking the composite structure out of the mandrel's surface.

The process shown on Figure 10 can also be used for the laying of the fibres. In this case, the fibres [[10.3], [15.3], [20.3]] are laid over the mandrel as shown on Figure 10.

Structural composites can also be made by inserting the reinforcement layers [15.5] between the metallic layers [15.3], hence creating a metallic composite with a structural reinforcement [15.4] in between the laminated layers [15.1]. The mandrel [15.2] gives the required shape to the composite structure.

Fibre- reinforced composites can also be made by the process shown on Figure 20. In this case, the adhesive [20.6] is laid between the metallic layers [20.3] and the fibre layers [20.5], hence creating a fibre reinforced composite, which is composed of reinforcement of fibre layers embedded in adhesive [20.4] embedded between layers of metallic material [20.1]. The mandrel [20.2] gives the required shape to the composite structure.

Another option is to perform the same process as that shown on Figure 10, but by each time inserting a separate adhesive-coated metallic layer in between the two layers (which are made by folding the same monolithic layer over and over again). This means that one monolithic adhesive-coated metallic foil layer [[11.3], [16.3], [21.3]] is being laid in between various separate adhesive-coated metallic foil layers [[11.4], [16.4], [21.4]], hence forming a metallic composite laminate based on one monolithic metallic foil layer [[11.1], [16.1], [21.1]] and various separate metallic foil layers [[11.4], [16.4], [21.4]]. The layers are laid over a mandrel [11.2] in order to obtained the required shape. Then, the mandrel with the layers still laid over

it is being placed in an autoclave in order to cure the adhesive before taking the composite structure out of the mandrel's surface.

The process shown on Figure 11 can also be used for the laying of the fibres. In this case, the fibres [[11.3], [16.3], [21.3]] are laid over the mandrel as shown on Figure 11.

Structural composites can also be made by inserting the reinforcement layers [16.5] between the metallic layers [16.3], hence creating a metallic composite with a structural reinforcement [16.4] in between the laminated layers [16.1]. The mandrel [16.2] gives the required shape to the composite structure.

Fibre-reinforced composites can also be made by the process shown on Figure 21. In this case, the adhesive [21.6] is laid between the metallic layers [21.3] and the fibre layers [21.5], hence creating a fibre reinforced composite, which is composed of reinforcement of fibre layers embedded in adhesive [21.4] embedded between layers of metallic material [21.1]. The mandrel [21.2] gives the required shape to the composite structure.

Another method is to perform the same process as that shown on Figure 11, but by each time inserting a separate adhesive-coated metallic layer in between the single folded layers (which are made by folding the same monolithic when folded again). This means that one monolithic adhesive-coated metallic foil layer [[12.3], [17.3], [22.3]] is being laid in between the two layers of another separate folded adhesive-coated metallic foil layer [[12.1], [17.1], [22.1]]. The metallic layer laid over the other separate layer [[12.1], [17.1], [22.1]] is then folded again, hence forming a metallic composite laminate. The separate layer [[12.1], [17.1], [22.1]] laid between the two layers is in turn folded and laid over the surface of the previous layer. This process is repeated successively until obtaining the required material thickness. The laminated layers [[12.1], [17.1], [22.1]] are laid over a mandrel [[12.2], [17.2], [22.2]] in

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order to obtained the required shape. Then, the mandrel with the layers still laid over it is being placed in an autoclave in order to cure the adhesive before taking the composite structure out of the mandrel's surface.

The process shown on Figure 12 can also be used for the laying of the fibres. In this case, the fibres [[12.3], [17.3], [22.3]] are laid over the mandrel as shown on Figure 12.

Structural composites can also be made by inserting the reinforcement layers [17.5] between the metallic layers [17.3], hence creating a metallic composite with a structural reinforcement [17.4] in between the laminated layers [17.1]. The mandrel [17.2] gives the required shape to the composite structure.

Fibre-reinforced composites can also be made by the process shown on Figure 22. In this case, the adhesive [22.6] is laid between the metallic layers [22.3] and the fibre layers [22.5], hence creating a fibre reinforced composite, which is composed of reinforcement of fibre layers embedded in adhesive [22.4] embedded between layers of metallic material [22.1]. The mandrel [22.2] gives the required shape to the composite structure.

Another method is to lay successively one or more adhesive-coated metallic layers [[13.3], [18.3], [23.3]] around a mandrel [[13.2], [18.2], [23.2]], hence forming a barrel-shaped structure based on a multilayer metallic composite energy storage-capable laminate composed of a single metallic adhesive-coated layer [[13.1], [18.1], [23.1]]. This is performed by winding the monolithic metallic layer around the mandrel successively until obtaining the required material thickness. The monolithic metallic layer can also be a multiple metallic laminate, which hence means it can be a layer made of two or more foils laminated together, hence creating a single layer. The single layer is then be wound around the mandrel in order to form a barrel-shaped structure. Then, the mandrel with the layers still

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laid over it is being placed in an autoclave in order to cure the adhesive before taking the composite structure out of the mandrel's surface. The structure created is a monolithic laminate structure based on only one layer (one component), hence resulting in only one connector needed to charge the energy-storage capable structure, and improved structural integrity.

The process shown on Figure 13 can also be used for the laying of the fibres. In this case, the fibres [[13.3], [18.3], [23.3]] are laid over the mandrel as shown on Figure 13.

Structural composites can also be made by inserting the reinforcement layers [18.5] between the metallic layers [18.3], hence creating a metallic composite with a structural reinforcement [18.4] in between the laminated layers [18.1]. The mandrel [18.2] gives the required shape to the composite structure.

Fibre-reinforced composites can also be made by the process shown on Figure 23. In this case, the adhesive [23.6] is laid between the metallic layers [23.3] and the fibre layers [23.5], hence creating a fibre reinforced composite, which is composed of reinforcement of fibre layers embedded in adhesive [23.4] embedded between layers of metallic material [23.1], The mandrel [23.2] gives the required shape to the composite structure.

Another method is to perform a similar process to that shown on Figure 12, but by inserting two separate metallic foils [27.1] which are each folded towards the opposite surface of the layer with which the layers concerned are laminated. The two layers [27.1] are folded inside the folded metallic layers [27.4], so that this laminating process is repeated successively until obtaining the required material thickness. This is performed by each time inserting two separate adhesive-coated metallic layers in between the single folded layer [27.4], which is made by folding the same monolithic layer). This means that two monolithic adhesive-coated

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metallic foil layers [27.1] are being laid in between the two folded layers of another folded separate adhesive-coated metallic foil layer [27.4]. The two metallic layers laid over the other separate folded layer [27.1] are then each folded towards the opposite direction, hence forming an even stronger composite laminate than what is shown on Figure 12. The two separate metallic layers laid between the folded layer [27.4] are in turn folded and are each laid over the opposite surface of the folded layer [27.4] in between which the two layers are embedded. This process is repeated successively until obtaining the required material thickness. The layers [27.3] are being laid over a mandrel [27.2] in order to obtained the required shape of the structure when the layers are laminated together. Then, the mandrel with the layers still laid over it is being placed in an autoclave in order to cure the adhesive before taking the composite structure out of the mandrel's surface.

The process shown on Figure 27 can also be used for the laying of the fibres. In this case, the fibres [27.3] are laid over the mandrel [27.2] as shown on Figure 27.

The process shown on Figure 27 can also be used for structural laminates using a similar method to that shown on Figures 14, 15, 16, 17 and 18, as well as for fibre reinforced composites using a similar method to that shown on Figure 19, 20, 21, 22 and 23.

The adhesive used in the material's manufacturing processes should be preferably a thermoset resin, and more preferably epoxy resin (both for the metallic layers' adhesive coating and fibre embedment adhesive layers).

The conductive material (conductor) used in the manufacturing of the conductive foil layers should be preferably metals or alloys, and most probably copper, aluminium, tin, or copper, aluminium and tin alloys. Additionally, the conductive material layers (preferably metallic)

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used in the manufacturing of the capacitor-capable composite materials should be preferably in the form of sheet, and most preferably in the form of foil or film.

In the manufacturing process of fibre-reinforced composites, the number of fibre layers in the material can be minimised by using a composite design in which long single fibre layers

[28.1] and folding them over the previous fibre layers [28.3] continuously until reaching the required material width (Figure 28), which means that the fibre layers [28.3] are laid in a direction parallel to the material's plain surface (along the material's plain surface) [28.4]. In this process, these are laid over the first layer of adhesive (not cured or optionally pre-cured)

[28.2], prior of being fully coated with the adhesive embedment layer [28.5], hence obtaining a fibre-reinforced composite material in which the number of fibres [28.3] which are present across the material's thickness is equivalent to the number of fibres present along the whole length of the composite structure concerned.

Preferred embodiments:

-Aerospace structures, such as aircraft fuselage sections, wing structures, empennage structures and space vehicle structures.

-Vehicle structures, such as car bodies, train bodies, truck bodies, buildings, aircraft structures, spacecraft structures, motorcycle structures, racing car structures, ship hulls, ship structures, naval structures, bus bodies and coach bodies, submarine structures, submarine hulls, shafts, internal combustion engine components, reciprocating compressor components, reciprocating engine components, turbomachine components, axial compressors, axial turbines, radial compressors, radial turbines.

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Claims

Claims:

1. A structural laminate material comprising a laminate which comprises multiple metallic film layers which are laminated together with optionally fibre layers embedded in an adhesive, thereby forming a capacitor.

2. A structural laminate material as claimed in claim 1, wherein the adhesive is an epoxy resin.

3. A structural laminate material as claimed in claims 1 and 2 wherein laminate in which each of the metallic layers are comprised of at least two metallic films fully coated and laminated together with insulating adhesive.

4. A structural laminate material as claimed in claims 1 to 3, in which the double metallic foil layers are used as a capacitor by taking one of the films as the positive pole and another film as the negative pole.

5. A structural laminate material as claimed in claims 1 to 4 in which the laminated metallic film layers are reinforced with fibres selected from carbon, glass, a metal or an alloy which are embedded in the adhesive.

6. A metallic laminate material as claimed in claims 1 to 5 in which the metallic foils can be made of a metal or an alloy, such as copper, aluminium or tin.

7. A structural laminate material as claimed in claims 1 to 6 in which the structure can be used for both electrical energy storage and structural functions.

8. A structural object comprising the structural laminate material as claimed in claims 1 to 7 which is made of the laminate concerned in which each of the 2 metallic films comprised

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in each monolithic double metallic layer features an electrical connection such that both poles can be connected together via a source of electromotive force in order to charge the structure with electrical energy.

9. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 8 whose manufacturing process starts by laminating two metallic foils together with adhesive.

10. A structural laminate material as claimed in claims 1 to 9 whose manufacturing process continues by pre-curing the double metallic foil layer after what is stated on claim 8 prior of laying the fibres on the metallic layers, which can be also prepared according to the process claimed in claim 9.

11. A structural laminate material as claimed in claims 1 to 10, which consists of a metallic foil electrical energy storage capable material in which the material's multiple layers are laid successively after laying a layer of adhesive on the previous layer until obtaining the required thickness of the structure.

12. The formation structure composed of a structural laminate material as claimed in claims 1 to 11 in which the same monolithic layers are successively laminated over each other until obtaining the required structural shape in which the number of metallic foils is at least 2 (the positive pole and the negative pole).

13. A structural laminate material as claimed in claims 1 to 11 which forms a monolithic capacitor formed by a layer of at least two metallic films laminated together embedded between various layers of fibre reinforcement embedded in adhesive.

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14. A structural laminate material as claimed in claims 1 to 13 metallic laminate whose structures are formed by laminating the multiple material layers over a mandrel.

15. A structure made of the structural laminate material as claimed in claims 1 to 14, which is aimed on claim 1 which can be formed by laminating a single monolithic double metallic film layer around a mandrel, hence forming a monolithic capacitor structure composed of a single metallic foil layer, which includes at least two laminated foils (2 metallic foils laminated together), optionally with reinforcement fibres embedded in adhesive.

16. A structural laminate material as claimed in claims 1 to 15 which is used as an energy storage device embedded inside the structure for car bodies, train bodies, truck bodies, buildings, aircraft structures, spacecraft structures, motorcycle structures, racing car structures, ship hulls, ship structures, naval structures, bus bodies and coach bodies, submarine structures, submarine hulls, shafts, internal combustion engine components, reciprocating compressor components, reciprocating engine components, turbomachine components, axial compressors, axial turbines, radial compressors, radial turbines.

17. A structural laminate material as claimed in claims 1 to 16 which comprises of a metallic fibre-reinforced composite laminate featuring double metallic foil layers using one foil as the as positive pole and the other foil as the negative pole.

18. A structural laminate material as claimed in claims 1 to 17 which comprises of a metallic fibre-reinforced composite laminates featuring triple metallic foil layers which use the two outer foils of the triple metallic layer as positive poles and the inner layer as the negative pole.

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19. A structural laminate material as claimed in claims 1 to 18 which comprises a metallic fibre reinforced laminate featuring triple metallic foil layers in which the two outer foils of each metallic layer can also be used as the negative pole and the inner foil as the positive pole.

20. A structural laminate material as claimed in claims 1 to 19 which comprises a metallic fibre-reinforced composite featuring quadruple adhesive-coated metallic foil layers in which each quadruple metallic layer can be used to act as a double capacitors, as the two positive pole foils are separated by the two negative pole foils.

21. A structural laminate material as claimed in claims 1 to 20 in which the reinforcement layers can be structural reinforcements (e.g. honeycomb), fibre reinforcements (e.g. glass, carbon, copper, tin, aluminium, iron, nylon, nanotube fibres), particle reinforcements (e.g. concrete), sandwich reinforcements (e.g. sheet, film and foil layers), or foam materials.

22. A structural laminate material as claimed in claims 1 to 21 which can comprise structural composites, particle-reinforced composites, or fibre-reinforced composites.

23. A structural laminate material as claimed in claims 1 to 22 whose laminate electrical conductor layers preferably in the form of sheet, and most preferably in the form of foil or film.

24. A structural laminate material as claimed in claims 1 to 23 which uses the reinforcement fibres as electrical conductors which are used as positive poles situated based negative poles and vice-versa, hence offering capacitance with the electrical conductive properties of the reinforcement fibres, therefore meaning that the reinforcement fibres should be

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preferably made of an electrical conductor (e.g. nylon), and most preferably of a metal (e.g. aluminium, copper, tin, iron) or an alloy.

25. A structural laminate material as claimed in claims 1 to 24 in which the positive pole fibres are aligned in parallel to the negative pole metallic foils, and vice-versa, which means that the negative pole fibres are aligned in parallel to the positive pole metallic foils.

26. A structural laminate material as claimed in claims 1 to 25 which comprises configuration in which each set of conductive reinforcement feature a different polarity (one fibre after the other) along the parallel direction to the metallic foils, hence creating capacitance between the fibres.

27. A structviral laminate material as claimed in claims 1 to 26 in which the metallic foil layers are each fully coated on both sides with an insulating adhesive layer, hence meaning that the adhesive-coated metallic layers are embedded between the reinforcement layers of the composite material.

28. A structural laminate material as claimed in claims 1 to 27 in which the reinforcement material comprises nanotube materials (e.g. carbon nanotube).

29. A structural laminate material as claimed in claims 1 to 28 which is comprised by a single long conductor layer (laminate made with at least two conductor foils) which is folded on itself continuously until obtaining the required material thickness, which can be reinforced between the folded layers with adhesive, or a mixture of adhesive and reinforcement (fibre, structural, or particle reinforcements).

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30. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 29 in which a single long conductor layer (laminate made with at least two conductor foils) is folded on itself continuously until obtaining the required material thickness, which can be optionally reinforced between the folded layers with adhesive, a mixture of adhesive and reinforcement (fibre, structural, or particle reinforcements), or by laying the adhesive after laying the reinforcement material, which hence results in the insertion of the reinforcement layers in between the folded conductor layers (laying the reinforcement layer over the previous layer prior of inserting the next layer).

31. A structural laminate material as claimed in claims 1 to 30 which is comprised by separate conductor layers (laminate made with at least two conductor foils) which are each folded on themselves only once, hence forming double layers which embed one layer of the next double layer formed by the next folded conductor foil until obtaining the required material thickness, which can be reinforced between the folded layers with adhesive, or a mixture of adhesive and reinforcement (fibre, structural, or particle reinforcements).

32. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 31 in which a separate conductor layers (laminate made with at least two conductor foils) which are each folded on themselves only once, hence forming double layers which embed one layer of the next double layer formed by the next folded conductor foil until obtaining the required material thickness, which is reinforced between the folded layers with adhesive, or a mixture of adhesive and reinforcement (fibre, structural, or particle reinforcements), or by laying the adhesive after laying the reinforcement material, which hence results in the insertion of the reinforcement layers in between the folded conductor

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layers (laying the reinforcement layer over the previous layer prior of inserting the next layer).

33. A structural laminate material as claimed in claims 1 to 32 which is comprised by separate conductor layers (laminate made with at least two conductor foils) which are each folded on themselves only one, hence forming double layers which embed at least two layers of the next double layers formed by the next folded conductor foils, with each layer being folded in the opposite direction to be laid over the opposite side of the layer which has contact with the layer concerned, hence obtaining the required material thickness, which can be reinforced between the folded layers with adhesive, or a mixture of adhesive and reinforcement (fibre, structural, or particle reinforcements).

34. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 33 in which separate conductor layers (laminate made with at least two conductor foils) which are each folded on themselves only one, hence forming double layers which embed at least two layers of the next double layers formed by the next folded conductor foils, with each layer being folded in the opposite direction to be laid over the opposite side of the layer which has contact with the layer concerned, hence continuing the same procedure repeatedly until obtaining the required material thickness, which can be reinforced between the folded layers with adhesive, or a mixture of adhesive and reinforcement (fibre, structural, or particle reinforcements), or by laying the adhesive after laying the reinforcement material, which hence results in the insertion of the reinforcement layers in between the folded conductor layers (laying the reinforcement layer over the previous layer prior of inserting the next layer).

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35. A structural laminate material as claimed in claims 1 to 34 which is comprised by a single conductor layer which is wound around itself (the next layer over the previous layer), in which reinforcement layers (e.g. laying adhesive after laying fibre layers) can optionally be laid in between the conductor layers (over the previous conductor layer prior of laying the next conductor layer), hence forming a monolithic barrel structure which offers capacitance capabilities.

36. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 35 in which a single conductor layer which is wound around itself over a barrel's surface which gives the required shape to the structure (the next layer over the previous layer), in which reinforcement layers (e.g. laying adhesive after laying fibre layers) can optionally be laid in between the conductor layers (over the previous conductor layer prior of laying the next conductor layer), hence creating a monolithic barrel structure.

37. A structural laminate material as claimed in claims 1 to 36 single long reinforcement fibre layers are folded on themselves continuously until obtaining the required material thickness, which can be reinforced with adhesive (embedded in adhesive), hence forming a monolithic structure which offers capacitance capabilities due to the conductive properties of the reinforcement fibres.

38. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 37 in which single long reinforcement fibre layers are folded on themselves continuously until obtaining the required material thickness, which can be reinforced with adhesive (embedded in adhesive), hence forming a monolithic structure which offers capacitance capabilities due to the conductive properties of the reinforcement fibres.

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39. A structural laminate material as claimed in claims 1 to 38 which is comprised by separate fibre reinforcement layers which are each folded on themselves only once, hence forming double layers which embed one layer of the next double layer formed by the next folded conductor foil until obtaining the required material thickness, which can be reinforced with adhesive (embedded in adhesive), hence forming a monolithic structure which offers capacitance capabilities due to the conductive properties of the reinforcement fibres.

40. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 39 in which separate reinforcement fibre layers are each folded on themselves only one, hence forming double layers which embed one layer of the next double layer formed by the next folded conductor foil until obtaining the required material thickness, which can be reinforced with adhesive (embedded in adhesive), hence forming a monolithic structure which offers capacitance capabilities due to the conductive properties of the reinforcement fibres.

41. A structural laminate material as claimed in claims 1 to 40 which is comprised by separate reinforcement fibre layers which are each folded on themselves only once, hence forming double layers which embed at least two layers of the next double layers formed by the next folded fibres, with each layer being folded in the opposite direction to be laid over the opposite side of the layer which has contact with the layer concerned, hence obtaining the required material thickness, which can be reinforced with adhesive (embedded in adhesive), hence forming a monolithic structure which offers capacitance capabilities due to the conductive properties of the reinforcement fibres.

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42. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 41 in which separate fibre reinforcement layers are each folded on themselves only once, hence forming double layers which embed at least two layers of the next double layers formed by the next folded reinforcement fibre layers, with each layer being folded in the opposite direction to be laid over the opposite side of the layer which has contact with the layer concerned, hence continuing the same procedure repeatedly until obtaining the required material thickness, which can be reinforced with adhesive (embedded in adhesive), hence forming a monolithic structure which offers capacitance capabilities due to the conductive properties of the reinforcement fibres.

43. A structural laminate material as claimed in claims 1 to 42 which is comprised by single fibre reinforcement layers which are wound around over themselves (the next layer over the previous layer), which can be reinforced with adhesive (embedded in adhesive), hence forming a monolithic barrel structure which offers capacitance capabilities due to the conductive properties of the reinforcement fibres.

44. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 43 in which single fibre reinforcement layers are wound around over themselves over a barrel's surface which gives the required shape to the structure (the next layer over the previous layer), which can be reinforced with adhesive (embedded in adhesive), hence creating a barrel structure which offers capacitance capabilities due to the conductive properties of the reinforcement fibres.

45. A structural laminate material as claimed in claims 1 to 44 which comprises laminated layers made of electrical conductor material, which are preferably comprised of at least one insulator adhesive-coated conductor foil (can also be sheet or film), and most

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preferably comprised of at least two insulator adhesive-coated conductor foils (can also be sheets or films) being laminated together.

46. A structural laminate material as claimed in claims 1 to 45 in which each set of positive pole and negative pole conductor foil layers (2 layers per set) feature electrical connectors in order to be able to connect them to a source of electromotive force in order to charge the conductive fibres with charge.

47. A structural laminate material as claimed in claims 1 to 46 in which long single fibre layers and folding them over the previous fibre layers continuously until reaching the required material width, which means that the fibre layers are laid in a direction parallel to the material's plain surface (along the material's plain surface), which are laid over the first layer of adhesive (not cured or optionally pre-cured), prior of being fully coated with the adhesive embedment layer.

48. A structural laminate material as claimed in claims 1 to 47 in which adhesive and conductive fibres (which are hence also used for capacitance purposes) feature electrical connectors in order to charge the capacitor coating fibres, and so to connect each positive and negative pole set of fibres (2 fibres per set) to a source of electromotive force in order to charge the conductive fibres with charge.

49. A structural laminate material as claimed in claims 1 to 48 which features electrical charging connectors, so, one per conductor layer and one per fibre (if the fibres are also used for capacitance purposes).

50. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 49 in which laminated layers are made of electrical conductor material, which are

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preferably comprised of at least one insulator adhesive-coated conductor foil (can also be sheet or film), and most preferably comprised of at least two insulator adhesive-coated conductor foils (can also be sheets or films) being laminated together.

51. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 50 in which each set of positive pole and negative pole conductor foil layers (2 layers per set) feature electrical connectors in order to be able to connect them to a source of electromotive force in order to charge the conductive fibres with charge.

52. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 51 in which long single fibre layers and folding them over the previous fibre layers continuously until reaching the required material width, which means that the fibre layers are laid in a direction parallel to the material's plain surface (along the material's plain surface), which are laid over the first layer of adhesive (not cured or optionally pre-cured), prior of being fully coated with the adhesive embedment layer.

53. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 52 in which both the adhesive and the conductive fibres (which are hence also used for capacitance purposes) feature electrical connectors in order to charge the capacitor coating fibres, and so to connect each positive and negative pole set of fibres (2 fibres per set) to a source of electromotive force in order to charge the conductive fibres with charge.

54. A process for the manufacturing of a structural laminate material as claimed in claims 1 to 53 in which electrical charging connectors, so, on per conductor layer and one per fibre (if the fibres are also used for capacitance purposes).

Amendments to the claims have been filed as follows

33 Claims:

1) A vehicle body structure comprising an element providing energy storage capability, wherein this element comprises a sandwich or laminate structure which comprises layers of a metallic material sandwiched between layers of an adhesive polymer resin.

2) An aerospace structure comprising structural components, preferably skin panels, according to claim 1.

3) A car body structure comprising structural components, preferably skin panels, according to claim 1.

4) A railcar body structure comprising structural components, preferably sheet panels, according to claim 1.

5) A truck body structure comprising structural components, preferably skin panels, according to claim 1.

6) A motorcycle body structure comprising structural components, preferably skin panels, according to claim 1.

7) A racing car body structure comprising structural components, preferably skin panels, according to claim 1.

8) A building structure comprising structural components, preferably wall panels, according l

to claim 1.

9) A naval structure, preferably a ship, comprising structural components, preferably sheet panels, according to claim 1.

10) A coach or bus body structure comprising structural components, preferably sheet panels, according to claim 1.

11) A shaft structure comprising structural components according to claim 1.

12) An internal combustion engine comprising structural components according to claim 1.

13) A reciprocating machine comprising structural components according to claim 1.

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14) A turbomachinery structure comprising structural components according to claim 1.