Battery Exterior Patterning for Flexible Composite Film Durability
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Solution Overview
Problem
Flexible electrochemical cells used in wearable devices face durability issues due to repetitive bending and straightening, leading to damage of the composite film that isolates the electrode assembly, resulting in performance and safety problems.
Innovation Solution
A pattern forming apparatus and method that uses a plate with holes and a punch assembly to create receiving and non-receiving regions on the exterior material of a battery, allowing for the formation of patterns that enhance flexibility and durability by managing tolerance and reducing failure rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a composite film is used as an exterior material for flexible batteries, then the battery can be completely isolated from the external environment, but the composite film may be damaged due to repetitive bending and straightening
Solution Approach 1:
The invention divides the exterior material into multiple layers with different functions: a flexible polymer layer that can bend repeatedly and a metal foil layer that provides isolation and strength. This segmentation allows each layer to perform its optimal function without compromising the other.
Solution Approach 2:
The invention uses a composite film structure consisting of a functional polymer layer and a metal foil layer laminated together. This composite structure combines the flexibility and bendability of the polymer with the strength and isolation properties of the metal foil, resolving the contradiction between flexibility and durability.
2Adaptability or versatility
If shape processing is performed on the composite film to impart flexibility, then the electrochemical cell can be made flexible, but the processing method is not clear and the shape processing is not performed in the thickness direction, degrading the durability
Solution Approach 1:
The invention performs shape processing in the thickness direction (vertical dimension) rather than only in the planar direction. By forming recessed portions and protruding portions through thickness-direction processing, the battery achieves flexibility while maintaining the integrity and durability of the composite film structure.
Solution Approach 2:
The invention applies shape processing locally at specific regions of the exterior material rather than uniformly across the entire surface. The recessed portions are formed at predetermined locations to provide flexibility where needed, while other regions maintain their original strength and isolation properties.
Data Source
AI summary
An apparatus for forming a pattern on an exterior material of a battery includes a plate that has a plurality of holes and includes a receiving region formation part configured to form a receiving region in an exterior material in a longitudinal direction of the battery and a non-receiving region formation part configured to form a non-receiving region enclosing the receiving region, and a punch assembly that has a plurality of punches corresponding to the plurality of holes and inserted into the plurality of holes to penetrate through the plate.