Laminated Power Storage Package with Exposed Metallic Foil Conductors
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Solution Overview
Problem
Laminated packaging materials used in power storage devices cannot expose metallic foils for conductive purposes, making it difficult to utilize them as conductors, as existing methods for cutting the resin layer do not effectively reveal a plane-shaped metallic area suitable for soldering or connection.
Innovation Solution
A package design for power storage devices that includes a laminated packaging material with a heat-resistant resin layer and a heat-fusible resin layer, where the heat-fusible resin layer is exposed to form conductive flanges, allowing partial exposure of the metallic foil for use as a conductor, eliminating the need for tab leads and reducing weight, size, and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If a laminated packaging material is used for power storage devices, then the package becomes thinner and lighter, but the metallic foil cannot be exposed for conductive purposes
Solution Approach 1:
The package is divided into a resin layer and a metallic foil layer, allowing selective exposure of the metallic foil at specific regions (flange portions) while maintaining the laminated structure for protection and sealing in other areas
Solution Approach 2:
The metallic foil is exposed only at specific local regions (flange portions) where conductive connection is needed, while the resin layer remains intact in other areas to provide protection and sealing, creating different functional zones within the same package structure
2Ease of manufacture
If laser processing is used to cut the resin layer, then a linear slit is formed, but the resin layer is not removed in a plane shape and the metallic foil cannot be exposed for soldering
Solution Approach 1:
The resin layer is removed in advance at the flange portions to expose the metallic foil before final assembly, creating pre-formed conductive areas that are ready for soldering without requiring additional processing steps
Solution Approach 2:
The conventional mechanical cutting method is replaced with a process that selectively removes the resin layer to expose the metallic foil in planar shapes, enabling soldering operations that require flat conductive surfaces
3Ease of operation
If insulated tab leads are pulled out from the package for wire connection, then the package cannot be used as a conductor, but additional components increase weight and complexity
Solution Approach 1:
The package structure itself serves multiple functions: it provides mechanical protection through the laminated design, enables sealing through the resin layer, and acts as a conductor through the exposed metallic foil portions, eliminating the need for separate tab lead components
Solution Approach 2:
The protective packaging function and the conductive connection function are merged into a single integrated structure, where the laminated packaging material itself serves as both the protective enclosure and the conductive element for electrical connection
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 solution enables the use of metallic foils as conductive sections within the package, reducing the weight and size of power storage devices, preventing electrolyte leakage, and avoiding short circuits, while improving production efficiency and safety by eliminating tab leads and direct joining of heat-fusible resin layers.
Implementation Method 1
peripheral edges of the first section and the second section of the at least one laminated packaging material are heat-sealed to form a storage chamber
Implementation Method 2
a heat-resistant resin layer adhered to the first surface of the metallic foil layer, and a heat-fusible resin layer adhered to the second surface of the metallic foil layer
Data Source
AI summary
A package for a power storage device includes at least one laminated packaging material having first and second sections. The packaging material includes a metallic foil layer, a heat-resistant resin layer, and a heat-fusible resin layer. In a state in which the heat-fusible resin layers of the first and second sections are faced, peripheral edges thereof are heat-sealed to form a storage chamber for accommodating a device main body. One of the sections is extended outside the storage chamber to form a conductive flange having an exposed heat-fusible resin layer. The conductive flange is provided with an external conductive section in which the heat-fusible resin layer is partially removed to expose the metallic foil layer. The packaging material having the external conductive section is provided with an internal conductive section in the storage chamber in which the heat-fusible resin layer is partially removed to expose the metallic foil layer.