Laminated Battery Sealing Structure for Right-Angle Layer Integrity
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Solution Overview
Problem
Laminated batteries face breakage issues at right-angled portions due to thin metal layers, leading to compromised sealability caused by the embossing process used in manufacturing.
Innovation Solution
A laminated battery design with a laminate exterior body comprising a resin layer and metal layer, where the metal layer thickness variation at right-angled and horizontal portions is controlled to maintain a ratio within 10%, and the use of crest-folded and trough-folded bent portions to enhance structural integrity and sealability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an embossing step is carried out to make the laminate film accord with the shape of the battery element, then the laminate exterior body can seal the battery element, but the metal layer thickness becomes thin at right-angled portions and breakage occurs
Solution Approach 1:
The patent changes the geometric parameters of the battery element by specifying that right-angled portions should have angles between 80° and 100° (substantially right-angled portions), and by controlling the metal layer thickness ratio at these portions to be within 10% of the thickness at horizontal portions. This parameter control prevents excessive thinning and breakage while maintaining sealability.
Solution Approach 2:
The patent applies local quality control by specifically addressing the metal layer thickness at right-angled portions versus horizontal portions. The thickness ratio constraint (|T1-T2|/T2×100 ≤ 10%) ensures that the metal layer maintains sufficient strength at critical right-angled portions while allowing necessary deformation for sealing at other areas.
2Shape
If the metal layer thickness is reduced to allow embossing, then the laminate film can conform to the battery element shape, but breakage occurs at thin portions
Solution Approach 1:
The patent establishes specific parameter ranges: right-angled portions with angles of 80°-100° and metal layer thickness ratios within 10% between right-angled and horizontal portions. These parameter constraints ensure the metal layer maintains sufficient thickness and strength to prevent breakage while still allowing the laminate film to conform to the battery element shape through controlled embossing.
3Weight of moving object
If the laminate exterior body is made thinner to reduce weight, then the battery becomes lighter, but the metal layer becomes prone to breakage at right-angled portions
Solution Approach 1:
The patent uses parameter control (thickness ratio ≤ 10% at right-angled portions) to optimize the metal layer design. This allows the laminate exterior body to be made as thin as possible for weight reduction while ensuring the metal layer maintains sufficient strength at critical right-angled portions through controlled thickness distribution.
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 controlled thickness and bent portion design effectively suppresses metal layer breakage and improves the sealability of the battery element, ensuring reliable performance.
Implementation Method 1
a laminate exterior body that seals the battery element
Data Source
AI summary
A laminated battery has a battery element and a laminate exterior body that seals the battery element. The laminate exterior body includes at least a resin layer and a metal layer that are laminated. The battery element includes substantially right-angled portions, and horizontal portions that are horizontal shaped. At 80% or more of areas of the metal layer that face the substantially right-angled portions of the battery element, a thickness T1 of the metal layer, with respect to a thickness T2 of the metal layer of the laminate exterior body that faces the horizontal portions of the battery element, satisfies a relationship of formula |T1−T2|/T2×100(%)≤10%.