Power Storage Package with Heat-Sealable Resin Layer
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Solution Overview
Problem
Conventional packaging for power storage devices, such as batteries and capacitors, face challenges in achieving further thinning and weight reduction while maintaining insulation and barrier properties, and require lengthy curing times for adhesive agents.
Innovation Solution
A package structure comprising a metal foil layer with an insulation layer laminated on at least one surface and a heat-sealable resin layer on the periphery, which secures insulation properties even with reduced thickness and eliminates the need for extensive adhesive application, allowing for faster production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the aluminum foil thickness is decreased to achieve thinning and weight saving, then the package becomes thinner and lighter, but pinholes are generated in the aluminum foil which compromises the barrier function
Solution Approach 1:
The package structure is segmented into multiple functional layers: a thin aluminum foil layer (5-20 μm) for light-weighting, a heat-resistant resin layer for barrier protection, and a thermoplastic resin layer for sealing. This segmentation allows each layer to specialize in one function, enabling the aluminum foil to be thinner without compromising overall barrier performance.
Solution Approach 2:
The package uses a composite structure combining aluminum foil with heat-resistant resin and thermoplastic resin layers. This composite material approach leverages the strengths of each material: aluminum provides light weight and basic barrier, heat-resistant resin provides pinhole protection and thermal stability, and thermoplastic resin provides sealability. The combination achieves both thinning and maintained reliability.
2Length of moving object
If the thermoplastic resin layer thickness is reduced to achieve further thinning, then the package becomes thinner, but sufficient heat seal strength cannot be secured
Solution Approach 1:
The invention optimizes the thickness parameter of the thermoplastic resin layer to a specific range (5-30 μm) that balances thinning goals with seal strength requirements. Additionally, the composition parameters of the thermoplastic resin are optimized to enhance sealability at reduced thickness, achieving both thinning and sufficient heat seal strength.
3Strength
If adhesive agents are used extensively to laminate layers, then strong bonding is achieved, but the curing time extends to about one week which increases production time
Solution Approach 1:
The invention extracts and eliminates the extensive adhesive agent lamination process from the package structure. Instead of using adhesive agents between layers, the design relies on direct lamination of the heat-resistant resin layer to the aluminum foil and the thermoplastic resin layer to the heat-resistant resin layer, achieving strong bonding without the need for time-consuming adhesive curing.
Solution Approach 2:
The package structure achieves self-bonding through the inherent properties of the materials. The heat-resistant resin layer and thermoplastic resin layer are designed to bond directly to adjacent layers through their own material properties rather than requiring external adhesive agents, thereby eliminating the curing wait time and enabling immediate subsequent processing.
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
This configuration enables significant thinning and weight saving of the package while maintaining insulation and barrier properties, and reduces production time by eliminating the need for lengthy adhesive curing.
Implementation Method 1
a heat-sealable resin layer provided on one surface of the metal foil layer or a region corresponding to a periphery of the one surface of the metal foil layer
Data Source
AI summary
A package for a power storage device includes a metal foil layer, an insulation layer laminated on at least center portion of one surface of the metal foil layer, and a heat-sealable resin layer arranged one surface of the metal foil layer or a region corresponding to a periphery of the one surface of the metal foil layer. With this, thinning, weight saving, and shortening of the production time can be attained.