Thermotropic Liquid Crystal Polymer Battery Casing with Nanoclay
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Solution Overview
Problem
There is a need for a battery casing with improved mechanical properties and moisture transmission resistivity to replace traditional metal casings, which are heavy and limited in shape/size, and aluminum casings that require complex manufacturing processes and are prone to performance degradation due to moisture ingress.
Innovation Solution
A battery casing made from a composite material comprising a thermotropic liquid crystal polymer and nanoclay, where the nanoclay is dispersed in an exfoliated state, providing enhanced impact strength and moisture barrier properties without the need for metal or aluminum components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal casings are used, then mechanical strength and durability are improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The patent uses a composite material consisting of thermotropic liquid crystal polymer and exfoliated nanoclay to create a battery casing that achieves high mechanical strength while maintaining low weight. The nanoclay reinforcement within the polymer matrix provides enhanced tensile strength and impact resistance comparable to metal casings, but with significantly reduced weight.
2Weight of moving object
If aluminum casings are used, then weight is reduced, but moisture transmission resistivity deteriorates and manufacturing complexity increases
Solution Approach 1:
The composite of thermotropic liquid crystal polymer and exfoliated nanoclay provides inherent moisture barrier properties without requiring additional aluminum layers or complex coatings. The nanoclay platelets create a tortuous path for moisture penetration, achieving excellent moisture transmission resistivity while maintaining the lightweight advantage.
Solution Approach 2:
The patent modifies the polymer matrix by incorporating nanoclay at optimized concentrations and achieving exfoliated dispersion, which fundamentally changes the material's barrier properties. This parameter change enables the plastic casing to achieve moisture resistance levels previously only attainable with metal or multi-layer composite structures.
3Reliability
If aluminum casings are used, then moisture barrier properties are improved, but manufacturing complexity and process difficulty increase
Solution Approach 1:
The patent develops a composite material that integrates moisture barrier functionality directly into the base polymer matrix through nanoclay incorporation. This eliminates the need for separate aluminum foil layers, adhesive bonding processes, and complex multi-step manufacturing procedures required by traditional aluminum-based battery casings.
4Ease of manufacture
If conventional polymer casings are used, then manufacturing simplicity is maintained, but impact strength and mechanical properties deteriorate
Solution Approach 1:
The patent enhances conventional polymer properties by incorporating exfoliated nanoclay at optimized loadings, which fundamentally improves impact strength and mechanical properties. The nanoclay reinforcement transforms the polymer from a weak, brittle material into a high-performance composite capable of withstanding mechanical stresses while maintaining ease of injection molding and manufacturing.
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 composite battery casing achieves improved mechanical properties, including impact strength and moisture transmission resistivity, while reducing weight and simplifying manufacturing, enabling lighter, more versatile battery modules for various electronic devices and electric transportation applications.
Implementation Method 1
at least a portion of the nanoclay is present in an exfoliated state
Implementation Method 2
a nanoclay dispersed in the thermotropic liquid crystal polymer
Implementation Method 3
improved moisture transmission resistivity
Data Source
AI summary
A battery casing including a container configured to house an electrode assembly, wherein the container includes a bottom wall and a plurality of side walls, the bottom wall and the plurality of side walls are integrated to define an open side opposite to the bottom wall and to define a space for housing the electrode assembly, at least one of the bottom wall and plurality of the side walls includes a composite including a thermotropic liquid crystal polymer and a nanoclay dispersed in the thermotropic liquid crystal polymer, wherein the main chain of the thermotropic liquid crystal polymer includes an aromatic oxycarbonyl repeating unit and an alkylene moiety-containing repeating unit, and at least a portion of the nanoclay is present in an exfoliated state, and an X-ray diffraction pattern of the composite does not exhibit an intrinsic peak corresponding to the nanoclay.