Battery Packaging Laminate for Corrosion-Resistant Adhesion
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Solution Overview
Problem
Conventional power storage device packaging materials face challenges in maintaining high adhesion between the barrier layer with a corrosion-resistant film and the adhesive layer, especially when water enters and reacts with the electrolyte, leading to corrosion of the barrier layer.
Innovation Solution
A power storage device packaging material comprising a laminate with a base material layer, a barrier layer, an adhesive layer, and a heat-sealable resin layer, where the adhesive layer is formed using a specific curing agent and a corrosion-resistant film with a P PO3/CrPO4 ratio within a specific range, analyzed by time-of-flight secondary ion mass spectrometry, and peak ratios from X-ray photoelectron spectroscopy, ensuring high adhesion even when water enters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional barrier layer with corrosion-resistant film is used, then corrosion resistance is improved, but adhesion to the adhesive layer deteriorates when water enters the device
Solution Approach 1:
The patent applies parameter changes by precisely controlling the composition ratio of phosphoric acid to chromium compound (P:Cr = 1:9 to 9:1) in the corrosion-resistant film. This specific compositional parameter ensures that the film maintains both corrosion resistance and adhesion to the adhesive layer even when water enters the device and reacts with the electrolyte to produce acid.
Solution Approach 2:
The patent uses a composite corrosion-resistant film containing both phosphoric acid and chromium compound components. This composite structure combines the corrosion resistance of chromium oxide with the adhesion properties of phosphoric acid, creating a multi-functional protective layer that addresses both corrosion protection and bonding requirements.
2Strength
If metallic packaging materials are used, then structural strength is improved, but weight reduction and shape adaptability are limited
Solution Approach 1:
The patent replaces rigid metallic packaging with a flexible laminate structure consisting of multiple thin film layers including a base material layer, barrier layer, adhesive layer, and heat-sealable resin layer. This thin-film construction achieves the required structural strength while enabling weight reduction and adaptability to diversified power storage device shapes.
Solution Approach 2:
The patent employs a composite laminate structure combining different material layers, each providing specific functions: the base material layer provides structural support, the barrier layer provides corrosion resistance, the adhesive layer provides bonding, and the heat-sealable resin layer provides sealing. This composite approach achieves metallic-level strength with non-metallic weight and flexibility.
3Reliability
If the corrosion-resistant film has high chromium content, then corrosion resistance is improved, but adhesion to the adhesive layer deteriorates
Solution Approach 1:
The patent optimizes the compositional parameters of the corrosion-resistant film by maintaining a specific P:Cr ratio between 1:9 and 9:1. This parameter optimization ensures that neither chromium nor phosphoric acid dominates, allowing the film to achieve both corrosion resistance and adhesion simultaneously. The balanced composition prevents the adhesion deterioration that occurs with high chromium content while maintaining corrosion protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution maintains high adhesion between the barrier layer and the adhesive layer, preventing corrosion and ensuring the integrity of the packaging material, even under conditions where water and electrolyte react.
Implementation Method 1
the adhesive layer is a cured product of a resin composition containing a compound having an isocyanate group
Implementation Method 2
a corrosion-resistant film is provided on a surface of the barrier layer, containing chromium fluoride and phosphoric acid
Implementation Method 3
when the corrosion-resistant film is analyzed using time-of-flight secondary ion mass spectrometry, a P PO3/CrPO4 ratio of peak intensity P PO3 derived from PO3-
Implementation Method 4
peak ratios from X-ray photoelectron spectroscopy
Data Source
Figure 1~3
Figure 4
AI summary
There is provided a power storage device packaging material that maintains high adhesion between a barrier layer having a corrosion-resistant film and an adhesive layer, even when water enters into the power storage device. The power storage device packaging material comprises a laminate comprising at least a base material layer, a barrier layer, an adhesive layer, and a heat-sealable resin layer in this order, wherein the adhesive layer is a cured product of a resin composition containing a compound having an isocyanate group; a corrosion-resistant film is provided on at least a surface of the barrier layer facing the adhesive layer; when the corrosion-resistant film is analyzed using time-of-flight secondary ion mass spectrometry, a PPO3/CrPO4 ratio of peak intensity PPO3 derived from PO3- to peak intensity PCrPO4 derived from CrPO4- is in the range of 6 to 120; when the corrosion-resistant film is analyzed by X-ray photoelectron spectroscopy, a peak POCO derived from C1s of O-C=O bonds in the range of 287 eV to 290 eV and a peak PC-C derived from Cls of C-C bonds at 285 eV are detected; and a value of peak height ratio POCO/C-C obtained by dividing a height of the peak POCO by a height of the peak PC-C is in the range of 0.10 or more and 0.50 or less.