Green & Cost-effective materials
The choice of the right materials was determined by the aspects of CO2 emissions reduction, the cost-effectiveness of the production technology, mechanical and magnetic properties and the weight of the moving wheels.
Graphene
eDI will utilize Stuart Licht's patent to create graphene from CO2 100x more cheaply than the current industry standard by using lithium carbonate and low-cost nickel and steel electrodes with low voltage current.
Both the wheels and chassis will be made from graphenes and carbon fibers. Because fewer graphene can be used to replace aluminum or steel, the realized cost can be even lower. Graphene is a very useful material in automotive industry as we show below.
At current prices, graphene produced in Licht's way can be 10-15 times less costly than steel while remaining stronger. In the first step CO2 is bubbled into, and dissolved in a molten lithium carbonate bath. Molten Li2CO3 (mp 723 °C) or low melting eutectics such as LiNaKCO3 (mp 399 °C) mixed with highly soluble Li2O absorbs the CO2. After that the carbon and oxides are split by electrolysis at electrodes immersed in the molten bath into oxygen at the electrode called the anode, and into carbon nanotubes at the electrode called the cathode. The process is further configured to subject the carbon nanotubes to an electrochemical exfoliation process to produce nano graphenes by using the cathode of the electrolysis device as the anode. The method is currently at TRL 5, therefore it is very likely that eDI will be able to use it in 1-2 years.
Light
More resistant, durable and lighter car pieces by incorporating graphene into the materials currently used in the structures and chassis of cars.
Slippery
Enhancement of lubricants: incorporating graphene to lubricants reduces friction and, at the same time, cools better the pieces exposed.
Sticky
More durable and stronger tires, and also better grip and less heating up, related to the thermal conductivity of graphene.
Zirconium oxide
Zirconium oxide (ZrO2) is a non magnetic and electrically insulating material and also has very high resistance to crack propagation, the fracture toughness is 6.5 MPa√m which makes it the most suitable material for the bearings inside the engine.
Polycarbonate
We use that grades of polycarbonate which is optically transparent. Its fracture toughness is 3 MPa√m and it is easily molded, and thermoformed. That's why it can perfectly replace the glass in the vehicle especially the semi-cylindrical shape windshield.
Teflon
Teflon (PTFE) has a low coefficient of friction and outstanding chemical and weathering resistance. It is soft, formable, exhibits excellent electrical insulating properties, and performs well at elevated temperatures up to 500°F. It is one of the best material to reduce the friction between the stator and the rotor and also insulate the air gap.