Graphene-Pyrene Battery Packaging for Bendable Moisture Barriers

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Solution Overview

Problem

Existing packaging for flexible secondary batteries fails to prevent cracks from occurring due to tensile and compressive stress in repeated bending environments, and also allows water and gas infiltration, leading to battery performance degradation.

Innovation Solution

A packaging solution comprising a first polymer resin layer, a multi-layered barrier layer that includes graphene, a dispersing agent, and pyrene as a flexible linking agent, and a second polymer resin layer, which blocks water and gas, maintains mechanical strength, and enhances flexibility and water barrier properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a tube packaging made of general polymer is used, then flexibility is provided, but water or air infiltrates through micropores and contaminates the electrolyte

Engineering Contradiction:

ImproveflexibilityVSAvoidwater and air infiltration

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The packaging uses a composite structure consisting of an inner layer (polymer resin providing flexibility), a middle layer (graphene-based barrier layer blocking water and gas), and an outer layer (polymer resin providing mechanical strength). This multi-material composite resolves the contradiction by combining the flexibility of polymer with the barrier properties of graphene.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If a packaging made of metal foil is used, then water and gas barrier properties are improved, but the battery cannot be completely bent and the metal foil may be torn off

Engineering Contradiction:

Improvewater and gas barrier propertiesVSAvoidflexibility and bendability

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The patent replaces rigid metal foil with thin film structures made of polymer resin and graphene. The graphene barrier layer is only 30-999 nm thick, making it flexible while maintaining water and gas blocking properties. This thin film approach eliminates the brittleness and tearing issues of metal foil while preserving barrier functionality.

Inventive Principle:

Principle #30Flexible shells and thin films

3Object-affected harmful factors

If the barrier layer is made thicker to improve water and gas blocking, then barrier properties are improved, but flexibility decreases and cracks occur in repeated bending

Engineering Contradiction:

Improvewater and gas blockingVSAvoidflexibility and crack resistance

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The patent optimizes the barrier layer thickness to 30-999 nm, which is sufficiently thin to maintain flexibility and resist cracking during bending, yet thick enough to effectively block water and gas molecules. This precise parameter control resolves the contradiction between barrier performance and flexibility.

Inventive Principle:

Principle #35Parameter changes

4Device complexity

If a single-layer barrier structure is used, then device complexity is reduced, but reliability in repeated bending environment deteriorates

Engineering Contradiction:

Improvepackaging structure complexityVSAvoidstability in repeated bending

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The packaging is segmented into three functional layers: an inner polymer resin layer for flexibility, a middle graphene-based barrier layer for water and gas blocking, and an outer polymer resin layer for mechanical strength. This segmentation allows each layer to perform its specific function optimally, enhancing overall reliability without excessive complexity.

Inventive Principle:

Principle #1Segmentation

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 effectively prevents battery performance degradation by blocking water and gas infiltration, maintaining mechanical strength, and enhancing flexibility, thereby ensuring stability and performance in repeated bending environments.

Implementation Method 1

a barrier layer which blocks water and gas

Methodology Applied

Scientific EffectPermeation barrier: Permeation

Implementation Method 2

comprises graphene, a dispersing agent, and pyrene as a flexible linking agent, in which there is π-π conjugation (interaction) between the graphene and the pyrene

Methodology Applied

Scientific Effectπ-π conjugation (interaction): Chemical Bonding

Data Source

PatentUS12327874B2Packaging for flexible secondary battery, and flexible secondary battery comprising same

Publication Date: 2025.06.10 LG ENERGY SOLUTION LTD

AI summary

Disclosed is a packaging for a flexible secondary battery comprising a first polymer resin layer, a barrier layer formed on the first polymer resin layer to block water and gas, and a second polymer resin layer formed on the barrier layer. The thickness of the barrier layer is 30 to 999 nm. The barrier layer is multi-layered, and comprises graphene, a dispersing agent, and pyrene as a flexible linking agent, in which there is π-π conjugation (interaction) between the graphene and the pyrene. Also disclosed is a flexible secondary battery comprising the packaging.