Abstract: With the continuous development of intelligent systems, driverless vehicles and other modern transportation, the lightweight, safety, payload and cycle life of traditional batteries have been faced with new challenges. In this paper, three different electrodes of carbon material were prepared by mixing activated carbon, mesoporous carbon and hybrid activated and mesoporous carbons. The microstructures and electrochemical properties of all three electrodes were compared and analyzed. A structural battery was fabricated by selecting the electrode presenting the best electrochemical performance integrated with ultra-thin carbon fiber reinforced polymer composite (UTCFRP). The mechanical properties were tested by a universal testing machine. The experimental results show that the electrode made of hybrid activated carbon and mesoporous carbon has a surface morphology that is more suitable for ions to migrate. The structural battery presents good charge and discharge characteristics. Under load conditions, the fluctuate of its specific capacitance and energy density is below 15% as the unit mass load of tensile test is less than 240 kN/kg; the specific capacitance and energy density increase by 39.5% as the unit mass load of compression test reaches 58 kN/kg, and the retention rate of the specific capacitance and energy density is 89% as the unit mass load of bending test reaches 41 kN/kg. As one kind of energy storage composite material, the structural battery with UTCFRP has great potential in improving the battery performance and realizing miniaturization and lightweight.

Key words: structural battery, integration of structure and function, ultrathin carbon fiber composite materials, service performance test