Flexible Battery Packaging Laminate for Deformation Resistance
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Solution Overview
Problem
Conventional battery packaging materials lack flexibility and resistance to deformation loads, making them unsuitable for applications in flexible devices such as wearable technology and soft robots, where batteries need to withstand frequent bending and deformation.
Innovation Solution
A battery packaging material comprising a metal layer and a substrate layer formed from a thermosetting resin composition with a cured tensile modulus of 10 kPa to 100 MPa at 25°C, which provides flexibility and resistance to deformation loads without the need for an additional adhesive layer, using thermosetting resin compositions like epoxy resins and polyrotaxane resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional packaging materials with high elastic modulus are used to secure barrier properties and toughness, then reliability is improved, but flexibility deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling the tensile modulus of the substrate layer within a specific range (10 MPa to 1000 MPa) to achieve both flexibility and reliability. By adjusting the elastic modulus parameter of the substrate material, the packaging can bend without breaking while maintaining barrier properties and toughness, thus resolving the contradiction between reliability and flexibility.
Solution Approach 2:
The patent uses composite materials by combining a metal layer with a substrate layer made of thermoplastic resin or elastomer. This composite structure integrates the barrier properties and strength of metal with the flexibility of polymer materials, achieving both high reliability and adaptability to deformation loads.
2Strength
If substrate layer with high tensile modulus is used to resist deformation loads, then strength is improved, but flexibility deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the tensile modulus of the substrate layer within the range of 10 MPa to 1000 MPa. This optimized parameter range allows the material to provide sufficient strength to resist deformation loads from frequent bending while maintaining enough flexibility for flexible battery applications.
Solution Approach 2:
The patent applies local quality by having different layers with different mechanical properties: the metal layer provides strength and barrier properties, while the substrate layer with controlled tensile modulus provides flexibility. This local differentiation of material properties allows the overall structure to achieve both strength and flexibility simultaneously.
3Weight of moving object
If thin laminate exterior materials are used to reduce battery weight, then weight is reduced, but flexibility deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling the thickness and tensile modulus of the substrate layer. By optimizing these parameters, the packaging can be made thin enough to reduce battery weight while maintaining sufficient flexibility through the controlled elastic modulus of the substrate material.
Solution Approach 2:
The patent uses composite materials where the combination of metal layer and polymer substrate layer creates a lightweight structure that is both thin and flexible. The polymer substrate provides flexibility and light weight, while the metal layer provides necessary strength and barrier properties.
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 packaging material exhibits high flexibility and durability, capable of safely and reliably sealing batteries, suitable for various battery types including flexible batteries, and maintains mechanical and chemical properties like toughness and heat resistance.
Implementation Method 1
a substrate layer which is formed of a thermosetting resin composition of which a cured product has a tensile modulus of 10 kPa or more and 100 MPa or less at 25° C.
Data Source
AI summary
An aspect of the present invention relates to a battery packaging material including: a metal layer, and a substrate layer laminated on at least one surface of the metal layer, in which the substrate layer is formed of a thermosetting resin composition of which the cured product has a tensile modulus of 10 kPa or more and 100 MPa or less at 25° C.