Thin Battery Foil Packaging Merging Electrode and Seal
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Solution Overview
Problem
Conventional thin batteries with laminated packaging materials face challenges in thickness and weight limitations due to separate electrode and packaging structures, requiring additional lead wires and increasing production complexity and weight.
Innovation Solution
A thin power storage device design where the metallic foil layers serve both as electrodes and packaging, eliminating the need for separate packaging materials and lead wires by integrating a peripheral sealing layer and insulation resin films, allowing for lightweight, thin, and space-saving construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laminated packaging material with resin films adhered on both surfaces of a metallic foil is used, then the battery structure is protected and assembled, but the total thickness becomes the sum of electrode main body thickness and packaging material thickness, exceeding thickness limitations
Solution Approach 1:
The patent merges the packaging material functions directly into the electrode structure by forming the peripheral sealing layer from the metallic foil itself rather than using separate packaging materials. The metallic foil serves dual purposes as both electrode current collector and packaging container, eliminating the need for additional resin film layers and reducing total thickness.
Solution Approach 2:
The metallic foil in the invention performs multiple functions simultaneously: it acts as the current collector for electrical conduction, provides structural support, forms the peripheral sealing for packaging, and serves as the container wall. This multi-functionality eliminates redundant components and reduces overall device thickness.
2Reliability
If tab lead wires are extended from electrodes and fixed at heat-sealed portions, then electrical connectivity is achieved, but the number of parts increases and production processes become more complex
Solution Approach 1:
The patent combines the lead wire function with the metallic foil structure itself. The peripheral sealing layer formed from the metallic foil directly provides the electrical connection path, eliminating the need for separate tab lead wires. The same metallic foil that forms the battery container also serves as the electrical conductor.
Solution Approach 2:
The metallic foil performs multiple functions including current collection, structural support, peripheral sealing, and electrical connection. By making the metallic foil multi-functional, the invention eliminates separate lead wires and reduces the number of assembly steps required for fixing electrical connections.
3Reliability
If tab lead wires are fixed at heat-sealed portions of laminated packaging material, then electrical connection is established, but the weight of the thin battery increases
Solution Approach 1:
The patent merges the electrical connection function into the metallic foil structure, eliminating separate lead wires and their associated weight. The metallic foil itself provides the electrical conduction path from the active material to the external terminal, removing the need for additional weighted components.
Solution Approach 2:
The metallic foil serves as current collector, structural support, sealing material, and electrical conductor simultaneously. This multi-functionality eliminates the need for separate lead wires and reduces overall battery weight by removing redundant materials.
4Ease of manufacture
If separate electrode main body and laminated packaging material are structured, then assembly is straightforward, but the number of parts increases and production becomes more troublesome
Solution Approach 1:
The patent combines the packaging material functions directly into the electrode structure by forming the peripheral sealing layer from the metallic foil itself. This integration reduces the number of separate parts that need to be assembled and simplifies the manufacturing process.
Solution Approach 2:
The metallic foil performs multiple functions including current collection, structural support, and peripheral sealing. By making the metallic foil multi-functional, the invention reduces the number of separate components and simplifies assembly procedures.
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 design achieves lightweighting, thinning, and cost reduction while ensuring sufficient insulation and electrical connectivity, extending the device's life by eliminating heat generation issues associated with lead wires and simplifying the mounting process.
Implementation Method 1
a peripheral sealing layer containing a thermoplastic resin, the peripheral region of the one surface of the first metallic foil layer and the peripheral region of the one surface of the second metallic foil layer are joined via the peripheral sealing layer
Data Source
AI summary
A power storage device includes a positive electrode part including a first metallic foil layer and a positive electrode active material layer partially laminated on one surface of the first metallic foil layer, a negative electrode part including a second metallic foil layer and a negative electrode active material layer partially laminated on one surface of the second metallic foil layer, and a separator arranged between the positive electrode part and the negative electrode part. The positive electrode active material layer is arranged between the first metallic foil layer and the separator, and the negative electrode active material layer is arranged between the second metallic foil layer and the separator. The peripheral regions of the one surfaces of the first and second metallic foil layers in which the positive and negative electrode active material layers are not formed are joined via a peripheral sealing layer containing a thermoplastic resin.