Battery Packaging Material Thickness Ratio Optimization
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Solution Overview
Problem
Conventional battery packaging materials face challenges in achieving a balance between thinness, moldability, piercing strength, and sealing properties, particularly in lithium batteries, where reducing thickness leads to increased pinhole generation and compromised sealing and insulation qualities.
Innovation Solution
A battery packaging material with a laminate structure comprising a base material layer, a metal layer, and a sealant layer, where the total thickness is maintained between 50 to 80 μm, and the ratio of the base material and metal layer thickness to the total thickness is set between 0.380 to 0.630, ensuring excellent moldability and piercing strength while improving sealing, insulation, and electrolytic solution resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the thickness of battery packaging material is reduced by equally thinning base material layer, metal foil layer and sealant layer, then weight reduction and thickness reduction are achieved, but the base material layer and metal layer become excessively thin leading to increased probability of pinhole generation during molding
Solution Approach 1:
The patent applies local quality by assigning different thickness ratios to different layers based on their specific functions. The base material layer and metal layer are given greater thickness (60-80% of total) to prevent pinholes during molding, while the sealant layer is kept thinner (20-40%) as it primarily needs to provide sealing rather than structural integrity during the molding process.
Solution Approach 2:
The patent changes the thickness parameters from equal distribution to a specific ratio distribution. By setting the thickness ratio of (base material layer + metal layer) to total thickness at 60-80%, and sealant layer to total thickness at 20-40%, the patent optimizes the balance between preventing pinholes and achieving thinness, rather than using uniform thinning.
2Length of moving object
If the base material layer becomes thin, then thickness reduction is achieved, but piercing strength is reduced leading to bag-breakage of lithium battery due to impact from outside
Solution Approach 1:
The patent assigns different thickness proportions to different layers based on their functional requirements. The base material layer and metal layer constitute 60-80% of total thickness to provide piercing strength and impact resistance, while the sealant layer comprises 20-40% as it requires less thickness for its sealing function.
Solution Approach 2:
The patent uses a composite laminate structure combining base material layer, metal layer, and sealant layer in specific thickness ratios. This composite structure allows the base material and metal layers to provide mechanical strength and piercing resistance, while the sealant layer provides sealing functionality, achieving both thinness and strength through material composition optimization.
3Length of moving object
If the sealant layer is thinned, then thickness reduction is achieved, but sealing property, insulation quality and electrolytic solution resistance are impaired
Solution Approach 1:
The patent optimizes the sealant layer thickness parameter by setting it at 20-40% of total thickness rather than equal distribution. This parameter optimization ensures sufficient sealing property, insulation quality, and electrolytic solution resistance while achieving overall thickness reduction of the battery packaging material.
Solution Approach 2:
The patent applies local quality by giving the sealant layer a specific thickness ratio (20-40% of total) that is sufficient for its sealing function but not excessive. The base material and metal layers receive greater thickness allocation (60-80%) to handle structural requirements, allowing the sealant layer to be optimized specifically for sealing performance.
4Strength
If metallic packaging materials are used, then strength and durability are maintained, but it is difficult to keep up with diversification in shape and there is a limit on weight reduction
Solution Approach 1:
The patent replaces metallic packaging with a composite laminate structure consisting of base material layer, metal layer, and sealant layer. This composite structure maintains strength and durability through the metal layer and base material layer while enabling shape diversification and weight reduction through the flexible laminate construction and optimized thickness ratios.
Solution Approach 2:
The patent uses a flexible laminate structure with optimized thickness ratios that allows the packaging material to be formed into diverse shapes. The thin film construction with base material layer (60-80% of total thickness) and sealant layer (20-40%) provides both flexibility for shape adaptation and sufficient strength for durability.
Data Source
AI summary
Provided is a battery packaging material that comprises a laminated body formed by sequentially stacking at least a base layer, a metal layer, and a sealant layer, and that has a thin overall thickness, and has excellent formability and piercing strength. This battery packaging material comprises a laminated body formed by sequentially stacking at least a base layer, a metal layer, and a sealant layer, with the overall thickness of the laminated body being 50-80 μm, and the ratio of the sum of the thicknesses of the base layer and the metal layer with respect to the overall thickness of the laminated body being in a range of 0.380-0.630.