MULTIFUNCTIONAL STRUCTURAL BATTERY COMPOSITES FOR ELECTRIC MOBILITY: DESIGN, SAFETY, AND SUSTAINABLE LIFE-CYCLE PERFORMANCE

Abstract

Structural battery composites are emerging as a promising multifunctional technology for lightweight electric mobility because they combine mechanical load-bearing capability with electrochemical energy storage in a single material system. This paper examines the design optimization, safety behavior, and life-cycle performance of structural battery composites for electric vehicle applications. The study highlights how carbon-fiber-reinforced electrodes, solid or semi-solid electrolytes, and multifunctional laminate architectures can reduce redundant vehicle mass while improving energy efficiency. The results indicate that optimized structural battery configurations can provide meaningful reductions in vehicle weight, improved stiffness-to-weight performance, and enhanced system-level efficiency compared with conventional battery pack integration. However, trade-offs remain between mechanical strength, ionic conductivity, energy density, impact resistance, and long-term durability. Safety analysis shows that damage tolerance, thermal stability, and electrolyte containment are critical factors for reliable adoption in mobility systems. Life-cycle assessment further suggests that structural batteries can reduce operational emissions through lightweighting benefits, although material sourcing, recycling complexity, and end-of-life separation must be carefully addressed. Overall, the findings demonstrate that structural battery composites can support the transition toward more efficient and sustainable electric mobility when material design, safety validation, and circular life-cycle strategies are integrated from the early development stage.