PAEK Battery Packaging with Embedded Metal Studs
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Solution Overview
Problem
Current lithium-ion battery packaging faces issues with long-term sealing in flexible designs and bulkiness, complexity, and electromagnetic interference in rigid designs, along with high weight and thermal conductivity concerns.
Innovation Solution
The use of polyaryletherketone (PAEK) sheets, preferably made of PEEK™, as packaging material, which can be flexible or rigid, incorporating metal studs to form the poles of the accumulator, eliminating the need for bulky connectors and ensuring a sealed and lightweight structure through self-adhesion, ultrasonic bonding, or freezing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flexible packaging made from multi-layered composite material (aluminium layers covered by polymer) is used, then the packaging can be sealed to contain the electrochemical cell, but long-term oxidation occurs in the positive pole causing loss of seal and electrolyte leakage
Solution Approach 1:
The patent uses a composite structure consisting of a polymer layer (PEEK or polypropylene) combined with an aluminium layer. The polymer layer provides oxidation resistance and chemical inertness, while the aluminium layer provides barrier properties and structural support. This composite material resolves the contradiction by preventing the oxidation that plagues flexible packaging over time, thereby maintaining sealing durability throughout the service life of the battery.
2Reliability
If rigid packaging with metal case is used, then long lifetime and high sealing degree are achieved, but the packaging becomes bulky and complex with increased weight
Solution Approach 1:
The patent employs thin flexible packaging layers (polymer and aluminium foils) that are much thinner than traditional rigid metal cases. These thin films provide adequate sealing and protection while dramatically reducing weight and bulk. The flexible nature of these thin films, when properly sealed, achieves the required sealing durability without the weight penalty of rigid metal construction.
3Reliability
If rigid metal packaging is used, then high sealing degree is achieved, but electromagnetic interference with nearby sensors and antennas occurs
Solution Approach 1:
The patent uses a polymer layer (PEEK or polypropylene) as the primary packaging material, which is inherently non-conductive and does not cause electromagnetic interference. The aluminium layer is applied locally only where structural support and barrier properties are needed, and its thickness is minimized. This local quality approach maintains sealing durability where required while eliminating electromagnetic interference in the regions where it would affect sensors and antennas.
4Reliability
If rigid metal packaging is used, then high sealing degree is achieved, but the packaging causes heating of the electrolyte due to high thermal conductivity
Solution Approach 1:
The patent uses thin flexible packaging layers with low thermal mass and moderate thermal conductivity. The polymer layer (PEEK or polypropylene) acts as a thermal insulator, while the thin aluminium layer provides barrier properties without significant heat conduction. This combination maintains sealing durability while preventing excessive heat transfer to the electrolyte, thereby avoiding electrolyte heating that would occur with thick rigid metal packaging.
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 PAEK-based packaging provides a durable, lightweight, and non-bulky solution with improved sealing and reduced electromagnetic interference, maintaining mechanical integrity and preventing electrolyte heating, suitable for various applications including aeronautical and space fields.
Implementation Method 1
freezing of a metal bar (9) to reduce its straight section to dimensions smaller than those of the opening
Implementation Method 2
holding of the frozen bar in the opening of the sheet at ambient temperature until it is adjusted whilst tightening, cutting of the bar along its straight section, once it has expanded and adjusted whilst tightening in the opening of the sheet
Data Source
AI summary
The invention concerns a new flexible or rigid packaging for an electrochemical accumulator (A).It is made from at least one polyaryletherketone (PAEK) sheet, notably a polyetheretherketone (PEEK™) sheet.According to a preferred embodiment, a polyaryletherketone (PAEK) sheet (6.1, 6.2, 6.3, 61) incorporates within it at least one metal stud (40, 50) constituting one of the poles of the accumulator. The main application sought is the packaging of lithium-ion accumulators.