Molding Packaging Material Black Ink Layer Cracking
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Solution Overview
Problem
Existing battery packaging materials with a print layer containing carbon black tend to crack and detach during molding or under harsh environments, such as hot and humid conditions, compromising the even black coloring of the battery.
Innovation Solution
A molding packaging material comprising a heat-resistant resin layer, a thermoplastic resin layer, a metal foil layer, and a black ink layer with carbon black, diamine, polyol, and a hardening agent, where the hardening agent constitutes 2 to 20 mass parts per 100 mass parts of carbon black and diamine/polyol, and a matt coated layer on the outer surface, preventing partial cracking and detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a print layer containing carbon black is provided on an inner surface of an outer resin layer to color a battery black, then the battery appearance is improved, but the print layer partially cracks and detaches during molding or under harsh environments
Solution Approach 1:
The patent applies composite materials by creating a multi-layer structure consisting of an outer resin layer, a print layer containing carbon black, and an inner resin layer. This composite structure allows each layer to perform its specific function: the outer layer provides appearance quality, the print layer provides black coloring, and the inner layer provides structural support and adhesion, thereby preventing crack and detachment issues while maintaining aesthetic appearance.
2Shape
If a deep-drawing or bulging molding process is used to form the battery case, then the case shape is created, but the print layer containing carbon black cracks and detaches
Solution Approach 1:
The patent applies segmentation by dividing the packaging material into distinct functional layers: an outer resin layer for appearance, a print layer for coloring, and an inner resin layer for structural integrity. This segmentation allows each layer to be optimized independently, with the inner layer providing the mechanical strength needed to withstand deep-drawing and bulging processes without causing the print layer to crack or detach.
Solution Approach 2:
The multi-layer composite structure enables the material to withstand molding processes by distributing mechanical stresses across different layers. The inner resin layer acts as a supportive backbone that maintains print layer integrity during deformation, while the outer layer maintains aesthetic appearance.
3Adaptability or versatility
If the battery is used under hot and humid environments, then the battery functions in various conditions, but the print layer detaches due to environmental stress
Solution Approach 1:
The multi-layer composite structure enhances environmental adaptability while maintaining print layer adhesion. The different resin materials in the outer and inner layers are selected to have complementary properties that resist hot and humid environmental conditions, creating a synergistic effect that protects the print layer from detachment under various environmental stresses.
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 effectively prevents partial cracking and detachment of the black ink layer during molding and under harsh environments, ensuring a consistent black color and improved adhesion, even in hot and humid conditions.
Implementation Method 1
a black ink layer arranged between the metal foil layer and the heat resistant resin layer, wherein the black ink layer contains carbon black, diamine, polyol, and a hardening agent
Implementation Method 2
an amount of the hardening agent contained in the black ink layer per 100 mass parts of a total amount of the carbon black, the diamine and the polyol of the black ink layer is 2 to 20 mass parts
Data Source
AI summary
The molding packaging material 1 according to the present invention includes a heat resistant resin layer 2 as an outer layer, a thermoplastic resin layer 3 as an inner layer, a metal foil layer 4 arranged between the heat resistant resin layer and the thermoplastic resin layer, and a black ink layer 10 arranged between the metal foil layer 4 and the heat resistant resin layer 2. The black ink layer 10 contains carbon black, diamine, polyol, and hardening agent. The black ink layer does not partially crack and detach even when the molding packaging material according to the present invention is used in a somewhat harsh environment such as a hot and humid environment and/or at the time of molding or sealing.