Laminated Battery Corner Adhesion Reinforcement
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Solution Overview
Problem
Laminated batteries face challenges in preventing moisture intrusion and sealing section breakage due to increased internal pressure, particularly during high-temperature storage or gas generation.
Innovation Solution
A laminated battery design featuring two laminated films with an adhesive resin layer, where the thickness of the resin layer is increased at the corner region of the sealing section to enhance adhesion strength and prevent breakage, and a manufacturing method involving a drawing process to form recesses and protrusions at the corner region with a varying load application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the adhesive resin layer thickness is increased at the corner region, then the adhesion strength and resistance to breakage are improved, but the manufacturing complexity increases due to the need for variable thickness control
Solution Approach 1:
The adhesive resin layer is designed with non-uniform thickness, being thicker at the corner region and thinner at other regions. This local quality variation provides enhanced adhesion strength specifically where stress concentration occurs at corners, while maintaining overall manufacturing feasibility through the embossing process that creates this thickness distribution.
Solution Approach 2:
The embossing process is performed on the sealing section before the actual sealing operation. This preliminary action creates the desired thickness distribution of the adhesive resin layer in advance, preparing the structure to better withstand future stress and pressure variations without requiring complex real-time control during sealing.
2Ease of manufacture
If a uniform adhesive resin layer thickness is used, then the manufacturing process is simpler, but the sealing section is more prone to breakage under internal pressure
Solution Approach 1:
Instead of using a uniform adhesive resin layer thickness throughout the sealing section, the design implements variable thickness with concentrated reinforcement at corner regions. This approach maintains relative manufacturing simplicity while significantly improving reliability by placing additional material precisely where stress concentration and breakage risk are highest.
3Volume of stationary object
If the corner radius is reduced to enhance volume efficiency, then the battery volume increases, but the stress concentration at corners increases leading to higher breakage risk
Solution Approach 1:
The adhesive resin layer thickness is specifically increased at corner regions, creating a local quality enhancement that compensates for the stress concentration caused by reduced corner radii. This allows the battery to achieve maximum volume efficiency with sharp corners while the reinforced adhesive layer prevents breakage at these high-stress locations.
Solution Approach 2:
The thicker adhesive resin layer at corner regions acts as a pre-established cushioning layer that absorbs and distributes stress before it can concentrate and cause breakage. This beforehand cushioning allows the use of smaller corner radii for volume efficiency while preventing the harmful effects of stress concentration.
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 design effectively inhibits moisture intrusion and prevents sealing section breakage even under increased internal pressure, while allowing for a reduced radius of curvature of the corner, thus enhancing the battery's structural integrity and volume efficiency.
Implementation Method 1
an outer structure formed by two laminated films each including an adhesive resin layer
Implementation Method 2
a depression that is to become a storage unit for the power generation element is formed through a drawing process and by pressing at least one of the laminated films with a pressing jig
Data Source
AI summary
A laminated battery provided with an electricity-producing element and an outer case. The electricity-producing element contains a positive electrode, a negative electrode, and an electrolyte. The outer case comprises two sheets of laminating film and includes the following: a containing section that contains the electricity-producing element; and a sealing section that is formed around the edge of the containing section by bonding the sheets of laminating film to each other. Corners are formed along the boundary between the containing section and the sealing section, and an adhesive resin layer in the sealing section is thicker in corner regions near the aforementioned corners than in other regions.