Battery Packaging Laminate for Sharp Deep-Draw Pouch Cases
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Solution Overview
Problem
The increasing demand for power storage devices with higher battery capacity and volume energy density requires packaging materials with improved molding workability, beyond just slipperiness, to form sharp and deep shapes effectively.
Innovation Solution
A packaging material with a laminated structure comprising a metal foil layer, a substrate layer, and a heat-fusible resin layer, where the heat-fusible resin layer is made of polyolefin-based film with Martens hardness between 15 N/mm2 and 25 N/mm2, and contains 500 mass ppm to 3,000 mass ppm of fatty acid amide-based lubricant, ensuring optimal compression resistance and followability during molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the packaging material is made to have good slipperiness by adding lubricant, then the slipperiness is improved, but the molding workability for sharp and deep shapes is insufficient
Solution Approach 1:
The invention changes the physical parameter of the heat-fusible resin layer by controlling its Martens hardness to a specific range (15-25 N/mm²) and adjusts the lubricant concentration (500-3000 mass ppm) to optimize both slipperiness and molding workability simultaneously
Solution Approach 2:
The packaging material uses a composite laminated structure comprising a metal foil layer, substrate layer, and heat-fusible resin layer, where each layer contributes different properties: the resin layer provides controlled hardness and slipperiness, the metal foil provides barrier properties, and the substrate provides structural support
2Ease of operation
If the packaging material is made to have high slipperiness by increasing lubricant content, then the slipperiness is improved, but lubricant bleeding occurs
Solution Approach 1:
The invention precisely controls the lubricant concentration parameter within 500-3000 mass ppm and the resin hardness within 15-25 N/mm², achieving optimal slipperiness while preventing lubricant bleeding through proper parameter optimization
Solution Approach 2:
The heat-fusible resin layer acts as an intermediary matrix that holds the lubricant particles, preventing them from migrating and bleeding while still providing the necessary slipperiness for molding operations
3Shape
If the packaging material is molded into sharp and deep shapes, then the shape complexity is improved, but delamination and constriction occur
Solution Approach 1:
By controlling the Martens hardness of the heat-fusible resin layer to 15-25 N/mm², the invention achieves the right balance between softness for conforming to sharp and deep shapes and strength for preventing delamination during the molding process
4Shape
If the packaging material is molded into sharp and deep shapes, then the shape complexity is improved, but constriction of the metal foil layer occurs
Solution Approach 1:
The laminated composite structure with the heat-fusible resin layer provides a cushioning effect that distributes molding stresses, preventing constriction of the metal foil layer while enabling the formation of sharp and deep shapes
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
This configuration enhances molding workability by reducing delamination and constriction, improving slipperiness, and preventing lubricant bleeding, allowing for the production of packaging cases with sharp and deep shapes while maintaining tooling and production line cleanliness.
Implementation Method 1
Martens hardness HMs of the heat-fusible resin layer measured with a Berkovich indenter is in a range of 15 N/mm2 to 25 N/mm2
Implementation Method 2
the film forming an inner surface of the packaging material contains 500 mass ppm to 3,000 mass ppm of a fatty acid amide-based lubricant
Data Source
AI summary
A packaging material for a power storage device includes a laminated material. The laminated material is composed of a metal foil layer, a substrate layer provided on an outer surface side of the metal foil layer, and a heat-fusible resin layer provided on an inner surface side of the metal foil layer. The heat-fusible resin layer is arranged on an inner surface side of the packaging material. The heat-fusible resin layer is formed of a polyolefin-based film. Martens hardness HMs of the heat-fusible resin layer measured with a Berkovich indenter is in a range of 15 N/mm2 to 25 N/mm2.