Resin Protective Layer on Metal Laminated Film Battery Casing

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Solution Overview

Problem

Non-aqueous electrolyte batteries using metal laminated films face challenges with poor strength and safety, particularly due to the thickness of resin molded cases and variations in electrolyte layer sizes, leading to defects and reduced productivity.

Innovation Solution

A non-aqueous electrolyte battery design featuring a film-form casing member with a uniform resin protective layer containing fiber materials, such as continuous or short fibers, and a thermosetting or photosetting resin, which improves strength and safety by forming a resin protective layer around the battery element and allowing for pressure relief through strategically placed openings in the sealing portion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a metal laminated film is used as a casing member material, then the battery weight is reduced and processing cost is reduced, but the battery strength becomes poor

Engineering Contradiction:

Improvebattery weightVSAvoidbattery strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent uses a composite structure consisting of a metal laminated film (providing light weight and low processing cost) combined with a resin molded case (providing strength and impact resistance). This composite approach allows the battery to achieve both weight reduction and adequate strength by combining the advantages of different materials.

Inventive Principle:

Principle #40Composite materials

2Strength

If the thickness of resin molded case is increased to improve battery strength, then manufacturing complexity and production cost increase

Engineering Contradiction:

Improvebattery strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent employs a thin resin molded case that is sufficiently thick to provide necessary strength and impact resistance, but not so thick as to create manufacturing complexity. The design optimizes the case thickness to achieve the minimum required protective function while maintaining ease of manufacturing.

Inventive Principle:

Principle #30Flexible shells and thin films

3Device complexity

If variations in electrolyte layer size are allowed to maintain simplicity, then manufacturing precision and productivity decrease

Engineering Contradiction:

Improvestructure simplicityVSAvoidmanufacturing productivity

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The patent specifies controlled parameter ranges for the electrolyte layer size to ensure consistent battery performance and manufacturing quality. By defining acceptable parameter variations, the patent maintains manufacturing precision without significantly increasing structural complexity.

Inventive Principle:

Principle #35Parameter changes

4Strength

If a resin molded case is used to improve battery strength, then the battery weight increases compared to using only metal laminated film

Engineering Contradiction:

Improvebattery strengthVSAvoidbattery weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent creates a composite casing structure where a thin resin molded case provides strength enhancement to a metal laminated film battery. This approach adds minimal weight while achieving the necessary strength improvement, as the resin case serves as a thin protective layer rather than a thick structural component.

Inventive Principle:

Principle #40Composite materials

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 enhances the strength and safety of the battery by preventing deformation and facilitating pressure relief, resulting in improved manufacturing efficiency and reduced defects, while maintaining a compact form factor.

Implementation Method 1

a film-form casing member with a uniform resin protective layer containing fiber materials, such as continuous or short fibers

Methodology Applied

Scientific EffectFiber reinforcement:

Implementation Method 2

a thermosetting or photosetting resin, which improves strength and safety by forming a resin protective layer around the battery element

Methodology Applied

Scientific EffectThermosetting:

Implementation Method 3

a thermosetting or photosetting resin

Methodology Applied

Scientific EffectPhotopolymerisation: Photopolymerisation

Implementation Method 4

improves strength and safety by forming a resin protective layer around the battery element

Methodology Applied

Scientific EffectMechanical constraint:

Implementation Method 5

allowing for pressure relief through strategically placed openings in the sealing portion

Methodology Applied

Scientific EffectPressure relief: Pressure Gradient

Data Source

PatentUS8450595B2Non-aqueous electrolyte battery and method for producing the same

Publication Date: 2013.05.28 MURATA MFG CO LTD

AI summary

A non-aqueous electrolyte battery includes a battery element, a film-form casing member, and a resin protective layer. The battery element includes a positive electrode, a negative electrode, and a separator disposed between the positive electrode and the negative electrode. The film-form casing member contains the battery element and an electrolyte in an enclosed space thereof. The resin protective layer is formed along the surface of the film-form casing member and has a substantially uniform thickness.