Aluminum Alloy Battery Packaging Foil for Crack-Free Thin Forming
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Solution Overview
Problem
Conventional metal battery packaging materials are difficult to shape into various forms and are limited in weight reduction, leading to challenges in reducing thickness without causing cracks and pinholes during molding.
Innovation Solution
A battery packaging material comprising a laminate structure with a base material layer, an aluminum alloy foil layer, and a heat-sealable resin layer, where the aluminum alloy foil meets JIS A8021 composition with 0.08% by mass or less Si, and specific grain and phase particle sizes, enhancing moldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the thickness of battery packaging material is reduced to meet size requirements, then weight and volume are reduced, but cracks and pinholes occur during molding
Solution Approach 1:
The patent changes the chemical composition parameters of the aluminum alloy foil layer by strictly controlling the Si content to 0.08% by mass or less and Fe content to 1.58% by mass or less. This parameter optimization improves the material's plasticity and moldability, enabling successful molding of thin-packaging materials without cracks or pinholes
Solution Approach 2:
The patent uses a laminate structure comprising a base material layer, an aluminum alloy foil layer with optimized composition, and a heat-sealable resin layer. This composite structure combines the advantages of different materials to achieve both thinness and high moldability, resolving the contradiction between reduced thickness and manufacturing quality
2Strength
If conventional metal packaging materials are used, then strength and durability are ensured, but various shapes and weight reduction are limited
Solution Approach 1:
The patent employs a laminate structure combining base material layer, optimized aluminum alloy foil layer, and heat-sealable resin layer. This composite design provides both the strength of metal and the formability of polymers, enabling various battery shapes while maintaining packaging integrity
Solution Approach 2:
The patent applies different materials with specific properties to different layers: the aluminum alloy foil layer provides strength and barrier properties, the base material layer provides structural support, and the heat-sealable resin layer provides sealing capability. This local optimization of material properties achieves both strength and shape adaptability
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 laminate structure provides improved moldability, allowing for thinner packaging materials with enhanced sealing strength and resistance to electrolytic solutions, ensuring crack-free and pinhole-free manufacturing.
Implementation Method 1
heat-sealable resin layers are thermally fused to obtain a battery in which the battery element is housed inside the battery packaging material
Data Source
AI summary
A battery packaging material includes a laminate with at least a base layer, an aluminum alloy foil layer, and a heat-fusible resin layer in this order, and in which the aluminum alloy foil layer satisfies the chemical composition in JIS A8021 and has a Si content of no higher than 0.08 mass %.