Author(s)

Boyan Shang

Corresponding Author

Boyan Shang

Abstract

The development of high-energy-density battery systems is critical to advancing drone technology for extended flight duration and enhanced payload capacity. This study presents a novel structural lithium-ion battery architecture integrating three key innovations: (1) carbon-fiber-composite structural electrodes enabling weight-efficient energy storage, (2) Mg-MOF-reinforced solid-state electrolytes addressing safety and dendrite suppression, and (3) gradient-doped high-nickel cathodes (NCM811) for improved cycle stability. The structural battery design achieves a gravimetric energy density of 427 Wh/kg by embedding graphene-coated carbon-fiber current collectors into a drone’s load-bearing frame, reducing system-level mass by eliminating redundant structural components. The composite solid-state electrolyte (PEO-15 wt% Mg-MOF-74) exhibits an ionic conductivity of 2.1 × 10⁻⁴ S/cm at 25°C and suppresses lithium dendrite formation through uniform Li⁺ flux regulation, enabling stable plating/stripping over 3,000 hours. A dual-strategy-modified NCM811 cathode (Al³⁺-graded doping and LiPO₂F₂ surface coating) retains 92.5% of initial capacity after 1,000 cycles at 1C, with reduced interfacial impedance (12 Ω•cm²) and Mn/Ni dissolution. Full-cell prototypes demonstrate 386 Wh/kg system-level energy density (38% higher than conventional Li-ion drones), 1,200-cycle lifespan (>80% retention), and thermal stability up to 150°C. Industrial feasibility assessments confirm compatibility with existing lithium-ion manufacturing infrastructure, with only a 12% cost increase per Wh compared to conventional systems. Structural simulations validate mechanical robustness under crash conditions, while flight tests show a 40% endurance extension in quadcopter drones. This work establishes a multifunctional battery framework that synergistically addresses energy density, safety, and manufacturability challenges, offering a practical pathway toward next-generation aerial platforms with extended operational capabilities.

Keywords

Structural Lithium-Ion Battery, Solid-State Electrolyte, High-Nickel Cathode (NCM811), Carbon Fiber Composite Electrode