WO2024040134A1 - Flexible packaging for use in energy storage devices, and method of manufacture thereof - Google Patents
Flexible packaging for use in energy storage devices, and method of manufacture thereof Download PDFInfo
- Publication number
- WO2024040134A1 WO2024040134A1 PCT/US2023/072336 US2023072336W WO2024040134A1 WO 2024040134 A1 WO2024040134 A1 WO 2024040134A1 US 2023072336 W US2023072336 W US 2023072336W WO 2024040134 A1 WO2024040134 A1 WO 2024040134A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- layer
- flexible packaging
- packaging material
- flexible
- metal foil
- Prior art date
Links
- 238000004146 energy storage Methods 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims description 40
- 238000009459 flexible packaging Methods 0.000 title description 12
- 238000004519 manufacturing process Methods 0.000 title description 7
- 239000010410 layer Substances 0.000 claims abstract description 162
- 239000005021 flexible packaging material Substances 0.000 claims abstract description 83
- 239000011888 foil Substances 0.000 claims abstract description 59
- 229910052751 metal Inorganic materials 0.000 claims abstract description 58
- 239000002184 metal Substances 0.000 claims abstract description 57
- 239000013013 elastic material Substances 0.000 claims abstract description 48
- 239000012812 sealant material Substances 0.000 claims abstract description 42
- 239000012790 adhesive layer Substances 0.000 claims abstract description 34
- 238000004806 packaging method and process Methods 0.000 claims abstract description 25
- 239000000463 material Substances 0.000 claims description 31
- -1 polypropylene Polymers 0.000 claims description 30
- 238000007789 sealing Methods 0.000 claims description 25
- 229920000642 polymer Polymers 0.000 claims description 24
- 239000000203 mixture Substances 0.000 claims description 21
- 239000003792 electrolyte Substances 0.000 claims description 20
- 229920001155 polypropylene Polymers 0.000 claims description 16
- 239000004743 Polypropylene Substances 0.000 claims description 13
- 239000005022 packaging material Substances 0.000 claims description 13
- 239000000853 adhesive Substances 0.000 claims description 12
- 230000001070 adhesive effect Effects 0.000 claims description 12
- 229920001577 copolymer Polymers 0.000 claims description 10
- 239000004677 Nylon Substances 0.000 claims description 7
- 229920001778 nylon Polymers 0.000 claims description 7
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 claims description 6
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 5
- 229920000098 polyolefin Polymers 0.000 claims description 5
- 238000010894 electron beam technology Methods 0.000 claims description 4
- 229920002635 polyurethane Polymers 0.000 claims description 4
- 239000004814 polyurethane Substances 0.000 claims description 4
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 claims description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 3
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 3
- 239000005977 Ethylene Substances 0.000 claims description 3
- 239000003522 acrylic cement Substances 0.000 claims description 3
- 229920006026 co-polymeric resin Polymers 0.000 claims description 3
- 150000001993 dienes Chemical class 0.000 claims description 3
- 229920002587 poly(1,3-butadiene) polymer Polymers 0.000 claims description 3
- 229920005989 resin Polymers 0.000 claims description 3
- 239000011347 resin Substances 0.000 claims description 3
- 125000000383 tetramethylene group Chemical group [H]C([H])([*:1])C([H])([H])C([H])([H])C([H])([H])[*:2] 0.000 claims description 3
- 239000012815 thermoplastic material Substances 0.000 claims description 3
- 229920005596 polymer binder Polymers 0.000 claims description 2
- 239000002491 polymer binding agent Substances 0.000 claims description 2
- 239000010408 film Substances 0.000 description 57
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 27
- 229910052799 carbon Inorganic materials 0.000 description 20
- 230000008569 process Effects 0.000 description 18
- 239000000654 additive Substances 0.000 description 16
- 239000011230 binding agent Substances 0.000 description 16
- 239000004094 surface-active agent Substances 0.000 description 15
- 230000000996 additive effect Effects 0.000 description 14
- 230000008901 benefit Effects 0.000 description 11
- 229910052782 aluminium Inorganic materials 0.000 description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 10
- 239000002482 conductive additive Substances 0.000 description 8
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 8
- 239000002904 solvent Substances 0.000 description 7
- 238000012360 testing method Methods 0.000 description 7
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 6
- 229910052744 lithium Inorganic materials 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- 239000000758 substrate Substances 0.000 description 6
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 5
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 5
- 239000011149 active material Substances 0.000 description 5
- 239000003795 chemical substances by application Substances 0.000 description 5
- 238000005530 etching Methods 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
- KMTRUDSVKNLOMY-UHFFFAOYSA-N Ethylene carbonate Chemical compound O=C1OCCO1 KMTRUDSVKNLOMY-UHFFFAOYSA-N 0.000 description 4
- 239000002033 PVDF binder Substances 0.000 description 4
- 239000000178 monomer Substances 0.000 description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 229920006380 polyphenylene oxide Polymers 0.000 description 4
- 229920005749 polyurethane resin Polymers 0.000 description 4
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 4
- 239000006254 rheological additive Substances 0.000 description 4
- 239000002002 slurry Substances 0.000 description 4
- 238000003860 storage Methods 0.000 description 4
- 229920001187 thermosetting polymer Polymers 0.000 description 4
- 229920002799 BoPET Polymers 0.000 description 3
- OIFBSDVPJOWBCH-UHFFFAOYSA-N Diethyl carbonate Chemical compound CCOC(=O)OCC OIFBSDVPJOWBCH-UHFFFAOYSA-N 0.000 description 3
- 229910012223 LiPFe Inorganic materials 0.000 description 3
- HBBGRARXTFLTSG-UHFFFAOYSA-N Lithium ion Chemical compound [Li+] HBBGRARXTFLTSG-UHFFFAOYSA-N 0.000 description 3
- 239000005041 Mylar™ Substances 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 229910006854 SnOx Inorganic materials 0.000 description 3
- 229920002125 Sokalan® Polymers 0.000 description 3
- 239000006183 anode active material Substances 0.000 description 3
- 238000003490 calendering Methods 0.000 description 3
- 239000002134 carbon nanofiber Substances 0.000 description 3
- 239000002041 carbon nanotube Substances 0.000 description 3
- 229910021393 carbon nanotube Inorganic materials 0.000 description 3
- 239000006182 cathode active material Substances 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- JBTWLSYIZRCDFO-UHFFFAOYSA-N ethyl methyl carbonate Chemical compound CCOC(=O)OC JBTWLSYIZRCDFO-UHFFFAOYSA-N 0.000 description 3
- 230000006870 function Effects 0.000 description 3
- 229910021389 graphene Inorganic materials 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 229910000625 lithium cobalt oxide Inorganic materials 0.000 description 3
- 229910001416 lithium ion Inorganic materials 0.000 description 3
- 229910002102 lithium manganese oxide Inorganic materials 0.000 description 3
- BFZPBUKRYWOWDV-UHFFFAOYSA-N lithium;oxido(oxo)cobalt Chemical compound [Li+].[O-][Co]=O BFZPBUKRYWOWDV-UHFFFAOYSA-N 0.000 description 3
- VLXXBCXTUVRROQ-UHFFFAOYSA-N lithium;oxido-oxo-(oxomanganiooxy)manganese Chemical compound [Li+].[O-][Mn](=O)O[Mn]=O VLXXBCXTUVRROQ-UHFFFAOYSA-N 0.000 description 3
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical class C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 3
- 229910001317 nickel manganese cobalt oxide (NMC) Inorganic materials 0.000 description 3
- 229910000480 nickel oxide Inorganic materials 0.000 description 3
- 239000003960 organic solvent Substances 0.000 description 3
- 150000002989 phenols Chemical class 0.000 description 3
- RUOJZAUFBMNUDX-UHFFFAOYSA-N propylene carbonate Chemical compound CC1COC(=O)O1 RUOJZAUFBMNUDX-UHFFFAOYSA-N 0.000 description 3
- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 229910052814 silicon oxide Inorganic materials 0.000 description 3
- VAYTZRYEBVHVLE-UHFFFAOYSA-N 1,3-dioxol-2-one Chemical compound O=C1OC=CO1 VAYTZRYEBVHVLE-UHFFFAOYSA-N 0.000 description 2
- MUZDXNQOSGWMJJ-UHFFFAOYSA-N 2-methylprop-2-enoic acid;prop-2-enoic acid Chemical compound OC(=O)C=C.CC(=C)C(O)=O MUZDXNQOSGWMJJ-UHFFFAOYSA-N 0.000 description 2
- SBLRHMKNNHXPHG-UHFFFAOYSA-N 4-fluoro-1,3-dioxolan-2-one Chemical compound FC1COC(=O)O1 SBLRHMKNNHXPHG-UHFFFAOYSA-N 0.000 description 2
- BTBUEUYNUDRHOZ-UHFFFAOYSA-N Borate Chemical compound [O-]B([O-])[O-] BTBUEUYNUDRHOZ-UHFFFAOYSA-N 0.000 description 2
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 2
- 239000005751 Copper oxide Substances 0.000 description 2
- WQZGKKKJIJFFOK-GASJEMHNSA-N Glucose Natural products OC[C@H]1OC(O)[C@H](O)[C@@H](O)[C@@H]1O WQZGKKKJIJFFOK-GASJEMHNSA-N 0.000 description 2
- SECXISVLQFMRJM-UHFFFAOYSA-N N-Methylpyrrolidone Chemical compound CN1CCCC1=O SECXISVLQFMRJM-UHFFFAOYSA-N 0.000 description 2
- 229920002302 Nylon 6,6 Polymers 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 229920000362 Polyethylene-block-poly(ethylene glycol) Polymers 0.000 description 2
- 229920002873 Polyethylenimine Polymers 0.000 description 2
- 229910008355 Si-Sn Inorganic materials 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- 229910006453 Si—Sn Inorganic materials 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 2
- 229940048053 acrylate Drugs 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- 239000002551 biofuel Substances 0.000 description 2
- 229920001400 block copolymer Polymers 0.000 description 2
- 239000005025 cast polypropylene Substances 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 229910000431 copper oxide Inorganic materials 0.000 description 2
- 239000013039 cover film Substances 0.000 description 2
- 239000004205 dimethyl polysiloxane Substances 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 239000008103 glucose Substances 0.000 description 2
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 2
- 229910003473 lithium bis(trifluoromethanesulfonyl)imide Inorganic materials 0.000 description 2
- 229910021450 lithium metal oxide Inorganic materials 0.000 description 2
- 229910003002 lithium salt Inorganic materials 0.000 description 2
- 159000000002 lithium salts Chemical class 0.000 description 2
- 229910001496 lithium tetrafluoroborate Inorganic materials 0.000 description 2
- QSZMZKBZAYQGRS-UHFFFAOYSA-N lithium;bis(trifluoromethylsulfonyl)azanide Chemical compound [Li+].FC(F)(F)S(=O)(=O)[N-]S(=O)(=O)C(F)(F)F QSZMZKBZAYQGRS-UHFFFAOYSA-N 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- CWQXQMHSOZUFJS-UHFFFAOYSA-N molybdenum disulfide Chemical compound S=[Mo]=S CWQXQMHSOZUFJS-UHFFFAOYSA-N 0.000 description 2
- 229910052982 molybdenum disulfide Inorganic materials 0.000 description 2
- 239000002070 nanowire Substances 0.000 description 2
- 229910052759 nickel Inorganic materials 0.000 description 2
- 235000006408 oxalic acid Nutrition 0.000 description 2
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 229920000435 poly(dimethylsiloxane) Polymers 0.000 description 2
- 229920000570 polyether Polymers 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 2
- 239000004810 polytetrafluoroethylene Substances 0.000 description 2
- 229920000036 polyvinylpyrrolidone Polymers 0.000 description 2
- 239000001267 polyvinylpyrrolidone Substances 0.000 description 2
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 229920003048 styrene butadiene rubber Polymers 0.000 description 2
- 229910052715 tantalum Inorganic materials 0.000 description 2
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 2
- 229910052718 tin Inorganic materials 0.000 description 2
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 2
- 229910001887 tin oxide Inorganic materials 0.000 description 2
- 238000009736 wetting Methods 0.000 description 2
- FSSPGSAQUIYDCN-UHFFFAOYSA-N 1,3-Propane sultone Chemical compound O=S1(=O)CCCO1 FSSPGSAQUIYDCN-UHFFFAOYSA-N 0.000 description 1
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- GXKAPTLUEUKNFJ-UHFFFAOYSA-N B([O-])(Cl)F.B([O-])(Cl)F.B([O-])(Cl)F.[Li+].[Li+].[Li+] Chemical compound B([O-])(Cl)F.B([O-])(Cl)F.B([O-])(Cl)F.[Li+].[Li+].[Li+] GXKAPTLUEUKNFJ-UHFFFAOYSA-N 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 229910016553 CuOx Inorganic materials 0.000 description 1
- 206010013786 Dry skin Diseases 0.000 description 1
- 239000002000 Electrolyte additive Substances 0.000 description 1
- 229910004271 Li(NiMnCo)O2 Inorganic materials 0.000 description 1
- 229910013098 LiBF2 Inorganic materials 0.000 description 1
- 229910052493 LiFePO4 Inorganic materials 0.000 description 1
- 229910010764 LiFeSO4F Inorganic materials 0.000 description 1
- 229910002995 LiNi0.8Co0.15Al0.05O2 Inorganic materials 0.000 description 1
- 229910012761 LiTiS2 Inorganic materials 0.000 description 1
- 229910002097 Lithium manganese(III,IV) oxide Inorganic materials 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 239000004820 Pressure-sensitive adhesive Substances 0.000 description 1
- 229910018540 Si C Inorganic materials 0.000 description 1
- 229910018537 Si SiOx Inorganic materials 0.000 description 1
- 229910008059 Si-SiOx Inorganic materials 0.000 description 1
- 229910000681 Silicon-tin Inorganic materials 0.000 description 1
- 229910002796 Si–Al Inorganic materials 0.000 description 1
- 229910006397 Si—SiOx Inorganic materials 0.000 description 1
- 229910006686 Si—Sn—C Inorganic materials 0.000 description 1
- 229910020813 Sn-C Inorganic materials 0.000 description 1
- 229910018732 Sn—C Inorganic materials 0.000 description 1
- 239000002174 Styrene-butadiene Substances 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 239000013504 Triton X-100 Substances 0.000 description 1
- 229920004890 Triton X-100 Polymers 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- 239000000443 aerosol Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- NDPGDHBNXZOBJS-UHFFFAOYSA-N aluminum lithium cobalt(2+) nickel(2+) oxygen(2-) Chemical compound [Li+].[O--].[O--].[O--].[O--].[Al+3].[Co++].[Ni++] NDPGDHBNXZOBJS-UHFFFAOYSA-N 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 239000003945 anionic surfactant Substances 0.000 description 1
- 239000003125 aqueous solvent Substances 0.000 description 1
- 239000003876 biosurfactant Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 description 1
- 239000003990 capacitor Substances 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000011852 carbon nanoparticle Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 239000003093 cationic surfactant Substances 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 150000004770 chalcogenides Chemical class 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000011889 copper foil Substances 0.000 description 1
- 238000003851 corona treatment Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 208000018999 crinkle Diseases 0.000 description 1
- 230000001351 cycling effect Effects 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- IEJIGPNLZYLLBP-UHFFFAOYSA-N dimethyl carbonate Chemical compound COC(=O)OC IEJIGPNLZYLLBP-UHFFFAOYSA-N 0.000 description 1
- QXYJCZRRLLQGCR-UHFFFAOYSA-N dioxomolybdenum Chemical compound O=[Mo]=O QXYJCZRRLLQGCR-UHFFFAOYSA-N 0.000 description 1
- 238000001523 electrospinning Methods 0.000 description 1
- 238000004945 emulsification Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 125000001153 fluoro group Chemical group F* 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910021385 hard carbon Inorganic materials 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 150000003949 imides Chemical class 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 230000016507 interphase Effects 0.000 description 1
- 229910052741 iridium Inorganic materials 0.000 description 1
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 1
- GELKBWJHTRAYNV-UHFFFAOYSA-K lithium iron phosphate Chemical compound [Li+].[Fe+2].[O-]P([O-])([O-])=O GELKBWJHTRAYNV-UHFFFAOYSA-K 0.000 description 1
- MHCFAGZWMAWTNR-UHFFFAOYSA-M lithium perchlorate Chemical compound [Li+].[O-]Cl(=O)(=O)=O MHCFAGZWMAWTNR-UHFFFAOYSA-M 0.000 description 1
- 229910001486 lithium perchlorate Inorganic materials 0.000 description 1
- ACFSQHQYDZIPRL-UHFFFAOYSA-N lithium;bis(1,1,2,2,2-pentafluoroethylsulfonyl)azanide Chemical compound [Li+].FC(F)(F)C(F)(F)S(=O)(=O)[N-]S(=O)(=O)C(F)(F)C(F)(F)F ACFSQHQYDZIPRL-UHFFFAOYSA-N 0.000 description 1
- VDVLPSWVDYJFRW-UHFFFAOYSA-N lithium;bis(fluorosulfonyl)azanide Chemical compound [Li+].FS(=O)(=O)[N-]S(F)(=O)=O VDVLPSWVDYJFRW-UHFFFAOYSA-N 0.000 description 1
- IGILRSKEFZLPKG-UHFFFAOYSA-M lithium;difluorophosphinate Chemical compound [Li+].[O-]P(F)(F)=O IGILRSKEFZLPKG-UHFFFAOYSA-M 0.000 description 1
- VGYDTVNNDKLMHX-UHFFFAOYSA-N lithium;manganese;nickel;oxocobalt Chemical compound [Li].[Mn].[Ni].[Co]=O VGYDTVNNDKLMHX-UHFFFAOYSA-N 0.000 description 1
- MCVFFRWZNYZUIJ-UHFFFAOYSA-M lithium;trifluoromethanesulfonate Chemical compound [Li+].[O-]S(=O)(=O)C(F)(F)F MCVFFRWZNYZUIJ-UHFFFAOYSA-M 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229910052976 metal sulfide Inorganic materials 0.000 description 1
- 229910000476 molybdenum oxide Inorganic materials 0.000 description 1
- 239000002086 nanomaterial Substances 0.000 description 1
- 239000002135 nanosheet Substances 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 229910000510 noble metal Inorganic materials 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- 239000010450 olivine Substances 0.000 description 1
- 229910052609 olivine Inorganic materials 0.000 description 1
- 229910052762 osmium Inorganic materials 0.000 description 1
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- PQQKPALAQIIWST-UHFFFAOYSA-N oxomolybdenum Chemical compound [Mo]=O PQQKPALAQIIWST-UHFFFAOYSA-N 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 229910052763 palladium Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000004584 polyacrylic acid Substances 0.000 description 1
- 229920001281 polyalkylene Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 239000011112 polyethylene naphthalate Substances 0.000 description 1
- 229920001451 polypropylene glycol Polymers 0.000 description 1
- 229920001289 polyvinyl ether Polymers 0.000 description 1
- 239000003361 porogen Substances 0.000 description 1
- 229910052702 rhenium Inorganic materials 0.000 description 1
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 1
- 229910052703 rhodium Inorganic materials 0.000 description 1
- 239000010948 rhodium Substances 0.000 description 1
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 1
- 238000007650 screen-printing Methods 0.000 description 1
- 239000000565 sealant Substances 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 229910021384 soft carbon Inorganic materials 0.000 description 1
- 239000007784 solid electrolyte Substances 0.000 description 1
- 238000005063 solubilization Methods 0.000 description 1
- 230000007928 solubilization Effects 0.000 description 1
- 238000004528 spin coating Methods 0.000 description 1
- 229910052596 spinel Inorganic materials 0.000 description 1
- 239000011029 spinel Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 239000011115 styrene butadiene Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229910000314 transition metal oxide Inorganic materials 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/06—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of natural rubber or synthetic rubber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/04—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B25/042—Layered products comprising a layer of natural or synthetic rubber comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material of natural rubber or synthetic rubber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/12—Layered products comprising a layer of natural or synthetic rubber comprising natural rubber
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/16—Layered products comprising a layer of natural or synthetic rubber comprising polydienes homopolymers or poly-halodienes homopolymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
- B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/03—3 layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2255/00—Coating on the layer surface
- B32B2255/20—Inorganic coating
- B32B2255/205—Metallic coating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/31—Heat sealable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/514—Oriented
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/732—Dimensional properties
- B32B2307/737—Dimensions, e.g. volume or area
- B32B2307/7375—Linear, e.g. length, distance or width
- B32B2307/7376—Thickness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2439/00—Containers; Receptacles
- B32B2439/02—Open containers
- B32B2439/06—Bags, sacks, sachets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/10—Batteries
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/16—Capacitors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/18—Fuel cells
Definitions
- the present disclosure generally relates to energy storage devices, such as batteries: thermoelectric and photoelectric, and supercapacitors. More specifically, the present disclosure relates to energy storage devices (e.g., electrochemical devices) with flexible packaging.
- energy storage devices e.g., electrochemical devices
- Energy storage devices include batteries, fuel cells, electrochemical sensors (e.g., glucose monitors) and bio-fuel cells.
- Typical existing energy storage devices e.g., batteries
- charge/discharge rates total energy, power performance, and the rigidity of the energy storage device itself.
- Flexible energy storage devices require each component (e.g., separator, electrodes, packaging, and electrolyte) to be durable and flexible without compromising the integrity and performance of the device.
- Traditional packaging may typically be formed from multilayer materials that can be sealed to form a pouch that will contain the other components of the energy storage device (e.g., separator, electrodes, and electrolyte).
- typical packaging does not meet emerging requirements for flexible energy storage devices. Therefore, there is a need for improved packaging for flexible energy storage devices.
- a flexible packaging material includes an elastic material layer; a metal foil layer; and a sealant material layer.
- a flexible packaging material includes an elastic material layer; a metal foil layer; and a sealant material layer; wherein the metal foil layer is disposed between the elastic material layer and the sealant material layer.
- the elastic material layer compnses a material selected from the group consisting of a thermoplastic material, a thermoset material, and combinations thereof.
- the elastic material layer comprises a polymer selected from the group consisting of a styrene polymer, an isoprene polymer, an ethylene polymer, a propylene polymer, a butadiene polymer, a butylene polymer, a diene polymer, a polyurethane polymer, an acetate polymer, copolymers thereof, and mixtures thereof.
- the elastic material layer comprises a thickness of about 50-100 pm.
- the metal foil layer comprises Al. In some embodiments, the metal foil layer comprises a thickness of about 20-60 pm. In some embodiments, the sealant material layer comprises a material selected from the group consisting of nylon (ONY), a polypropylene (PP) resin, an ethylene and acrylic acid (EAA) a copolymer resin, copolymers thereof, orientations thereof, and mixtures thereof. In some embodiments, the sealant material layer comprises a thickness of about 30-100 pm.
- the flexible packaging material further comprises at least one interlaminar adhesive layer.
- a position of the at least one interlaminar adhesive layer is selected from the group consisting of disposed between the elastic material layer and the metal foil layer, disposed between the metal foil layer and the sealant material layer, and combinations thereof.
- the at least one interlaminar adhesive layer comprises a material selected from the group consisting of a urethane adhesive, an acrylic adhesive, a polyolefin adhesive, and combinations thereof.
- the at least one interlaminar adhesive layer comprises a thickness of about 5-15 pm.
- a flexible energy storage device in another aspect, includes a flexible packaging material; a cathode; an anode; and a separator disposed between the another and the cathode.
- the flexible energy storage device further comprises an electrolyte.
- at least one of the cathode and the anode comprises an electron beam cured polymer binder.
- a method of forming a flexible energy storage device includes disposing an energy storage device assembly between a top packaging material and a bottom packaging material, wherein the top and bottom packaging materials each comprise a flexible packaging material; sealing the top and bottom packaging materials to form a sealed packaging, wherein the energy storage device assembly and the sealed packaging form the flexible energy storage device.
- sealing comprises a sealing temperature of about 130-210°C. In some embodiments, sealing comprises a sealing pressure of about 25-60 psi. In some embodiments, sealing comprises a sealing time of about 2-10 second.
- a method of forming a flexible packaging material includes disposing a metal foil layer over an elastic material layer; and disposing a sealant material layer over the metal foil layer.
- the method further comprises disposing a first interlaminar adhesive layer over the elastic material layer, and disposing the metal foil layer over the first interlaminar adhesive layer. In some embodiments, the method further comprises disposing a second interlaminar adhesive layer over the metal foil layer, and disposing the sealant material layer over the second interlaminar adhesive layer.
- FIG. 1 is an illustration of a cathode, separator and anode assembly, according to some embodiments.
- FIG. 2 is an illustration of an energy storage device, according to some embodiments.
- FIG. 3A is an illustration of a flexible packaging material, according to some embodiments.
- FIG. 3B is an illustration of a flexible packaging material with interlaminar adhesive layers, according to some embodiments.
- FIG. 4 is an illustration of a flexible packaging material, according to some embodiments.
- FIG. 5A is an illustration of a process of preparing a flexible packaging material, according to some embodiments.
- FIG. 5B is an illustration of a process of preparing a flexible packaging material with interlaminar adhesive layers, according to some embodiments.
- FIG. 6 is an illustration of a process of preparing a flexible packaging material, according to some embodiments.
- FIG. 7 is an illustration of a process of sealing a cathode, separator and anode assembly within a flexible packaging, according to some embodiments.
- FIG. 8A is an illustration of a control packaging material used to form a packaging of an energy' storage device.
- FIG. 8B is an illustration of a flexible packaging material used to form a packaging of a flexible energy storage device, according to some embodiments.
- FIG. 8C is an illustration of a flexible packaging material used to form a packaging of a flexible energy storage device, according to some embodiments.
- FIG. 9 shows a voltage v. time graph depicting the charge/discharge results of a control energy storage device and a flexible energy storage device, according to some embodiments.
- the flexible packaging material comprises multiple layers of materials.
- the multiple layers include an elastic material layer used as a base material, a metal foil layer and a sealant material layer, to build a robust, impermeable dielectric film for the energy storage device (e.g., battery) packaging.
- the use of an elastic material layer allows for the formation of a flexible packaging with improved flexibility, durability, confonnability, and/or stretchability, while simultaneously sealing the other components of the energy storage device (e.g., separator, electrodes, and electrolyte) within the packaging.
- the flexible packaging formed from the flexible packaging material is or is substantially impermeable water and air, and resistant to degradation due to the operation of the energy storage device itself and/or electrolyte contained within.
- the energy' storage (e.g., electrochemical) device may include a battery.
- the energy storage (e.g., electrochemical) device may include fuel cells, electrochemical sensors (glucose monitors), bio-fuel cells, and combinations thereof.
- the disclosed energy storage device e.g., battery
- the disclosed energy storage device may be a solid-state energy storage device.
- FIG. 1 illustrates an assembly 100 comprising a cathode 102, a separator 104, and an anode 106.
- the electrodes i.e., cathode 102 and anode 1066 each comprise an electrode film disposed over a current collector.
- the electrode films comprise an active material and a binder, and may further comprise additional elements such as a conductive additive.
- the electrode film of the anode 106 includes active material particles, a binder, and conductive additive particles and/or nanostructures in certain embodiments.
- FIG. 2 is an illustration of an assembled die cut shaped energy storage device 200.
- the energy storage device 200 includes an anode 202 and a cathode 206 separated by a separator 204, which is encased in a packaging 210.
- the anode 202 is in electrical contact with a current collector 208A
- the cathode 206 is in electrical contact with a current collector 208B.
- the components of the energy storage device 200 are shown disposed over a substrate 212.
- the energy storage device 200 further includes anode and cathode electrical connectors (e.g., leads and/or tabs) from the anode and cathode cunent collectors 208 A, 208B, respectively, coming out of the sealed film and/or are exposed in order for the energy storage device 200 to make electrical connections with a device in need thereof.
- the substrate 212 also comprises a material the same, substantially the same or similar to the material of the packaging 210, such that the packaging 210 and substrate 212 form a seal and encapsulate the anode 202, cathode 206 and separator 204 to form a water-impermeable and/or oxygen-impermeable packaging.
- the packaging 210 and substrate 212 each are or comprise a flexible packaging material described herein.
- the energy storage device 200 can be a primary or rechargeable energy storage device, and in various forms. Prior to assembly and sealing the cell of the energy storage device 200, the device 200 may be filled with an electrolyte.
- the energy storage device 200 is a battery, a capacitor, or a combination thereof.
- the energy storage device 200 is a solid state energy' storage device such that the energy storage device 200 includes a solid state electrolyte positioned between the cathode 206 and the anode 202.
- the solid state electrolyte is in a semisolid (e.g., gel) or solid form.
- the energy storage device 200 can include a first electrode 202, 206 that includes a first current collector 208 A, 208B in contact with a first electrode film (e.g., a cathode electrode with a cathode electrode film), and a second electrode 202, 206 that includes a second current collector 208A, 208B in contact with a second electrode film (e.g., an anode electrode with an anode electrode film).
- the first current collector 208A, 208B and the second current collector 208A, 208B may facilitate electrical coupling between each corresponding electrode film and an external circuit (not shown).
- the current collector 208A, 208B (i.e., base layer) can include a metallic material, such as a material comprising aluminum, nickel, copper, rhenium, niobium, tantalum, and noble metals such as silver, gold, platinum, palladium, rhodium, osmium, iridium and alloys and combinations of the foregoing.
- the current collector 208A, 208B can comprise a metal foil, for example, a nickel foil, an aluminum foil, a carbon foil, a copper foil, a carbon coated metal foil, or a tantalum coated metal foil.
- the current collector 208A, 208B may include copper, aluminum, and coated metal foils, and combinations thereof.
- the electrode 202, 206 can include at least one electrode film on or disposed over a surface of the current collector 208A, 208B.
- the electrode 202, 206 may be a multilayer electrode and comprise more than one electrode film, for example, such as a first electrode film and a second electrode film disposed on the same or different sides of the current collector 208A, 208B.
- the multilayered electrode is heterogeneous such that the properties, loading, thickness and/or composition of a first electrode film is different than that of a second electrode film of the electrode.
- the electrode film may comprise a cathode active material or an anode active material.
- the electrode film and/or electrode film mixture comprises the active material in, in about, in at least, or in at least about, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 90 wt.%, 92 wt.%, 95 wt.%, 97 wt.%, 98 wt.% or 99 wt.%, or any range of values therebetween.
- the cathode active material can include, for example, carbon monofluoride (CFx), metal oxide, metal sulfide, or a lithium metal oxide.
- the lithium metal oxide can be, for example, a lithium nickel manganese cobalt oxide (NMC), a lithium manganese oxide (LMO), a lithium iron phosphate (LFP), a lithium cobalt oxide (LCO), a lithium titanate (LTO), and/or a lithium nickel cobalt aluminum oxide (NCA).
- NMC lithium nickel manganese cobalt oxide
- LMO lithium manganese oxide
- LFP lithium iron phosphate
- LCO lithium cobalt oxide
- LTO lithium titanate
- NCA lithium nickel cobalt aluminum oxide
- cathode active materials can comprise, for example, a layered transition metal oxide (such as LiCoCh (LCO), Li(NiMnCo)O2 (NMC) and/or LiNi0.8Co0.15Al0.05O2 (NCA)), a spinel manganese oxide (such as LiMn2O4 (LMO) and/or LiMm.5Nio.5O4 (LMNO)), an olivine (such as LiFePO4), chalcogenides (LiTiS2), tavorite (LiFeSO4F), silicon, silicon oxide (SiOx), aluminum, tin, tin oxide (SnOx), manganese oxide (MnOx), molybdenum oxide (MOO2), molybdenum disulfide (M0S2), nickel oxide (NiOx), or copper oxide (CuOx).
- a layered transition metal oxide such as LiCoCh (LCO), Li(NiMnCo)O2 (NMC)
- the anode active materials can include, for example, an insertion material (such as carbon, graphite (natural, synthetic or blends), hard or amorphous carbons and/or graphene), an alloy ing/dealloying material (such as silicon, silicon oxide, tin, and/or tin oxide), a metallic element, metal alloy or compound (such as Si-Al, and/or Si-Sn), and/or a conversion material (such as manganese oxide, molybdenum oxide, nickel oxide, and/or copper oxide).
- an insertion material such as carbon, graphite (natural, synthetic or blends), hard or amorphous carbons and/or graphene
- an alloy ing/dealloying material such as silicon, silicon oxide, tin, and/or tin oxide
- a metallic element, metal alloy or compound such as Si-Al, and/or Si-Sn
- a conversion material such as manganese oxide, molybdenum oxide, nickel oxide, and/or copper oxide.
- the anode active materials can be used alone or mixed together to form multi-phase materials (such as Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si- SiOx-C, Sn-SnOx-C, Si-Sn-C, SiOx-SnOx-C, Si-SiOx-Sn, or Sn-SiOx-SnOx ).
- multi-phase materials such as Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si- SiOx-C, Si-SiOx-Sn, or Sn-SiOx-SnOx ).
- the electrode film and/or electrode film mixture can comprise a binder.
- the electrode film comprises the binder in, in about, in at most, in at most about, 0.5 wt.%, 1 wt.%, 2 wt.%, 3 wt.%. 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt.%, or any range of values therebetween.
- the binder is a polymerizable binder.
- the polymerizable binder is electron beam (“e-beam” or “EB”) polymerizable and/or curable.
- Binders may include an acrylated polyurethane resin (e.g. Ucecoat 7689, Ucecoat 7510, and Ucecoat 7690 (i.e. a polyurethane acrylate, acry late ester and/or acrylated monomer dispersion in water)), a hydroxy modified acrylated polyurethane resin (e g., hydroxy modified Ucecoat 7690), an acrylate-methacrylate monomer blend (e.g. Ebecryl 109), a monoacrylate of mono-ethoxylated phenol (e.g.
- Ebecryl 114 trimethylolpropane ethoxy triacrylate (TMPEOTA), an acrylonitrile and/or acrylamide (e.g., LA133), polytetrafluoroethylene (PTFE), a polyolefin, polyalkylenes, polyethers, styrene-butadiene, co-polymers of polysiloxanes, a polysiloxane, branched polyethers, polyvinylethers, polyacrylic acid (PAA), styrene-butadiene rubber (SBR), copolymers thereof, and/or admixtures thereof.
- the binder can include a cellulose, for example, carboxymethylcellulose (CMC).
- the polyolefin can include polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), copolymers thereof, and/or mixtures thereof.
- the binder can include polyvinylene chloride, poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), poly(ethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block- poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxanecoalkylmethylsiloxane, co-polymers thereof, and/or admixtures thereof.
- the binder may include an acrylated polyurethane resin, an acrylatemethacrylate monomer blend, a monoacrylate of mono-ethoxylated phenol, polyvinylidene fluoride (PVDF), and combinations thereof.
- the binder may include an acrylated polyurethane resin, an acrylate-methacrylate monomer blend, a monoacrylate of mono-ethoxylated phenol, and combinations thereof.
- the electrode film and/or electrode film mixture can comprise an additive.
- the electrode film and/or electrode film mixture comprises the additive in, in about, in at most, in at most about, 0.05 wt.%, 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1 wt.%, 1.5 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt.%, or any range of values therebetween.
- the additive is a conductive additive, a rheological additive, an etching additive, or combinations thereof.
- the additive is a conductive additive.
- conductive additives may be selected from carbon black, carbon nanoparticles, a graphitic material, graphite, graphene-containing materials, hard carbon, soft carbon, carbon nanotubes, carbon nanofibers, porous carbon, conductive carbon, a high- aspect ratio conductive additive or a combination thereof.
- the graphitic material can be a surface treated material.
- the porous carbon can comprise activated carbon.
- the porous carbon can comprise hierarchically structured carbon.
- the porous carbon can include structured carbon nanotubes, structured carbon nano wires and/or structured carbon nanosheets. In some embodiments, the porous carbon can include graphene sheets. In some embodiments, the porous carbon can be a surface treated carbon. In some embodiments, the high-aspect ratio conductive additive is selected from a carbon nanofiber, a carbon nanotube, a chopped carbon nanofiber, a nanowire, a chopped metal thread, and combinations thereof. In some embodiments, the chopped metal thread comprises a metal nickel, copper, silver, and combinations thereof. The high aspect ratio fibers allow the battery electrodes to maintain electrical contact during the deformation. In some embodiments, the additive is a rheological additive.
- a rheological additive includes oxalic acid.
- the additive is an etching additive.
- the etching additive is added to the electrode film mixture and/or to the current collector to remove or reduce the oxidation layer of a current collector once applied, thereby allowing the electrode film to strongly adhere to the current collector (e.g., resulting in improved electrical conductivity and battery performance).
- an etching additive includes oxalic acid, nitric acid, HC1, or combinations thereof.
- the electrode film may comprise a surfactant.
- the surfactant is selected from a hydrocarbon surfactant, a fluoro surfactant, a silicon surfactant, a polyoxypropylene surfactant, and combinations thereof.
- the surfactant is selected from an amphiphilic surfactant, a cationic surfactant, an anionic surfactant, a non-ionic surfactant, a polymeric surfactant, a biosurfactant, and combinations thereof.
- surfactants include polyethylene glycol derivatives (e g., Triton X-100 ) (molecular weight 695 g/mol to 1,000.000 g/mol)), polyvinylpyrrolidone (PVP), cationic poly(ethyleneimine) (PEI, molecular weight 10,000 g/mol to 1,000.000 g/mol), and anionic poly(acrylic acid) (PAA, molecular weight 15,000 g/mol to 1,000.000 g/mol).
- surfactant provides properties such as reduced surface tension and energy, emulsifi cation, dispersion and solubilization for casting and/or dry ing of the electrode film.
- surfactants include structure-directing agents, carbon sources, porogen agents and stabilizer agents.
- the surfactant includes a molecular weight of, of about, of at most, or of at most about, 300 g/mol, 500 g/mol, 600 g/mol, 700 g/mol, 800 g/mol, 1,000 g/mol, 2,000 g/mol, 5,000 g/mol, 10,000 g/mol, 15,000 g/mol, 20,000 g/mol, 30,000 g/mol, 40,000 g/mol, 50,000 g/mol, 60,000 g/mol or 80,000 g/mol, or any range of values therebetween.
- the electrode film and/or electrode film mixture comprises the surfactant in, in about, in at most, in at most about, 0.001 wt.%, 0.005 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, 0.06 wt.%, 0.07 wt.%, 0.08 wt.%, 0.09 wt.%, 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.
- the energy storage device 200 can include any number of different types of electrolyte.
- the device 200 can include a lithium ion battery electrolyte, which can include a lithium source, such as a lithium salt, and a solvent, such as an organic solvent.
- the device can further include an electrolyte additive, such as solid electrolyte interphase (SEI)-forming additive, an electrode wetting additive, or a separator wetting additive.
- SEI solid electrolyte interphase
- a lithium salt can include lithium hexafluorophosphate (LiPFe), lithium tetrafluoroborate (LiBF4), lithium perchlorate (LiC'IOi).
- lithium bis(trifluoromethansulfonyl)imide LiNCSChCFg lithium trifluoromethansulfonate (LiSOsCFs), lithium bis(pentafluoroethanesulfonyl)imide (C4FioLiN04S2), lithium bis(fluorosulfonyl)imide (F2LiNO4S2), lithium bis(oxalato)borate (LiB(C2 ⁇ )4)2), lithium difluoro(oxalato) borate (LiBF2(C2C>4), lithium difluorophosphate (FgLiChP), lithium oxalyldifluoroborate, lithium trifluorochloroborate (LiBFsCl), lithium hexafluoroarsenate (LiAsFs), lithium bis(trifluoromethanesulfonyl)imide (LiTFSi), combinations thereof, and/or the like.
- a lithium ion electrolyte solvent can include one or more ethers and/or esters.
- a lithium ion electrolyte solvent may comprise ethylene carbonate (EC), dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), vinyl carbonate (VC), propylene carbonate (PC), fluoroethylene carbonate (FEC), 1,3-propane sultone (PS), combinations thereof, and/or the like.
- the electrolyte may comprise LiPFe, ethylene carbonate, propylene carbonate and diethyl carbonate.
- the device can include a solid state electrolyte.
- Electrodes described herein may be prepared by various processes.
- an electrode film mixture e.g. comprising the active material, binder, and optionally additives
- a solvent is an aqueous solvent, an organic solvent, or a combination thereof.
- an electrode film mixture e.g. comprising the active material, binder, and optionally additives
- the electrode film mixture further comprises a surfactant and/or an additive (e.g.
- the solvent includes water, N-methylpyrrolidone (NMP), other organic solvents, or combinations thereof.
- NMP N-methylpyrrolidone
- the electrode film slurry may then be cast upon a substrate to form an as-cast electrode film.
- casting of the electrode film slurry may be performed using a doctor blade, spray coating, comma bar, slot die, aerosol, gravure, screen printing, imprinting, spin-coating, electrospinning, ultrasonic spray, electrostatic spray, and combinations thereof.
- the as-cast electrode film may then be dried and/or cured to form an electrode film.
- the as-cast electrode film or electrode film is calendered (e.g.
- the as-cast electrode film or electrode film is not calendered.
- the electrode film may be formed using dry materials, such as a calendering process.
- the substrate which the dry electrode film or electrode film slurry is cast upon is a current collector, and as such an electrode is formed once the electrode film is deposited, dried and/or cured.
- Drying may be performed by heating (e.g., vacuum heating and/or convection heating) the as-cast electrode film to evaporate the solvent. Curing may be performed to polymerize the binder to form a binder matrix within the electrode film. In some embodiments, curing is performed by an energy source, such as for example photons and/or electrons. In some embodiments, curing is performed by an electron beam (“e- beam” or “EB”). In some embodiments, the curing is performed with an EB with, with about, with at least, or with at least about, 50 kV, 100 kV, 150 kV, 200 kV, 250 kV 300 kV, or any range of values therebetween.
- e- beam electron beam
- the curing is performed with an EB with, with about, with at least, or with at least about, 15 kGy, 20 kGy, 25 kGy, 30 kGy, 40 kGy, 50 kGy, 60 kGy, 70 kGy, 80 kGy or 100 kGy, or any range of values therebetween.
- Flexible Packaging Material
- the flexible packaging material comprises an elastic material layer, a metal foil layer and a sealant material layer.
- the elastic material layer comprises an elastic polymer.
- the elastic material layer comprises a thermoplastic material, a thermoset material, or combinations thereof.
- the elastic polymer comprises a thermoplastic polymer, a thermoset polymer, or combinations thereof.
- the elastic polymer comprises a styrene polymer, an isoprene polymer, an ethylene polymer, a propylene polymer, a butadiene polymer, a butylene polymer, a diene polymer, a polyurethane polymer, an acetate polymer (e.g., vinyl acetate), copolymers thereof (e.g., block copolymers, for example such as A-B or A-B-A block copolymers), and mixtures thereof.
- the elastic material layer may comprise or consist of a thermoset material (e.g., Panasonic BeyolexTM).
- the elastic material layer is, is about, is at least, or is at least about, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 110 pm, 120 pm, 130 pm, 140 pm, 150 pm, 160 pm, 170 pm, 180 pm, 190 pm or 200 pm, or any range of values therebetween.
- the flexible packaging material comprises, or comprises at least, 1, 2, 3, 4 or 5 layers, or any range of values therebetween, of the elastic material layer.
- the metal foil layer is impermeable or substantially impermeable to oxygen and/or water.
- the metal foil layer comprises aluminum.
- the metal foil layer comprises an aluminum (“Al”) foil or coating.
- the metal foil layer is coated on and/or disposed over the elastic material layer.
- the metal foil layer comprises at least one surface that is surface treated.
- the metal foil layer is, is about, is at least, or is at least about, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm or 100 pm, or any range of values therebetween.
- the flexible packaging material comprises, or comprises at least, 1, 2, 3, 4 or 5 layers, or any range of values therebetween, of the metal foil layer.
- the sealant material layer may be used to seal the flexible packaging material to form a packaging, for example by sealing together the sealant materials layers from two or more flexible packaging materials.
- the sealant material layer is impermeable or substantially impermeable to oxygen and/or water.
- the sealant material layer comprises a sealant material.
- the sealant material comprises a thermal adhesive.
- the sealant material comprises nylon (“ONY”), a polypropylene (PP) resin (e.g., cast polypropylene (CPP), blown polypropylene (BPP) and other variants), an ethylene and acrylic acid (EAA) copolymer resin, copolymers thereof, orientations thereof (e.g., bi- axially oriented), and/or mixtures thereof.
- PP polypropylene
- CPP cast polypropylene
- BPP blown polypropylene
- EAA ethylene and acrylic acid copolymer resin
- orientations thereof e.g., bi- axially oriented
- mixtures thereof e.g., bi- axially oriented
- the sealant material is, is about, is at least, or is at least about, 3 pm, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 110 pm, 120 pm, 130 pm, 140 pm, 150 pm or 200 pm, or any range of values therebetween.
- the flexible packaging material comprises, or comprises at least, 1, 2, 3, 4 or 5 layers, or any range of values therebetween, of the sealant material layer.
- the flexible packaging material may comprise at least one intermediate or interlaminar layer.
- the intermediate or interlaminar layer may comprise a material selected from polyethylene terephthalate (“PET”), an adhesive (e.g., a pressure sensitive adhesive (“PSA”)), a polypropylene (e.g., a polypropylene (“PP”) film), and combinations thereof.
- the PSA is selected from a urethane adhesive (e.g., Loctite Liofol LA 3649 adhesive and LA 6255 curing agent), an acrylic adhesive, a polyolefin adhesive, and combinations thereof.
- the intermediate or interlaminar layer is, is about, is at least, or is at least about, 1 pm, 2 pm, 3 pm, 4 pm, 5 pm, 6 pm, 7 pm, 8 pm, 9 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm or 100 pm, or any range of values therebetween.
- the flexible packaging material comprises, or comprises at least, 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 layers, or any range of values therebetween, of the intermediate or interlaminar layer.
- one or more layers of the flexible packaging material may be treated.
- the treatment is a chemical treatment, surface treatment, or combinations thereof.
- the treatment may include a corona treatment.
- the treatment may improve adhesion between surfaces of adjacent layers.
- FIG. 3A is an illustration of a flexible packaging material, wherein the flexible packaging material comprises an elastic material layer, a metal foil layer disposed over the elastic material layer, and a sealant material layer disposed over the metal foil layer.
- FIG. 3B is an illustration of a flexible packaging material with interlaminar adhesive layers, wherein the flexible packaging material comprises an elastic material layer, a first interlaminar adhesive layer disposed over the elastic material layer, a metal foil layer disposed over the first interlaminar adhesive layer, a second interlaminar adhesive layer disposed over the metal foil layer, and a sealant material layer disposed over the second interlaminar adhesive layer.
- FIG. 4 is an illustration of an example flexible packaging material.
- the flexible packaging material comprises an elastic material layer, an Al metal foil layer disposed over the elastic material layer, and a biaxially oriented nylon-6, 6 sealant material layer disposed over the metal foil layer.
- the flexible packaging material comprises 100 pm of a BeyolexTM elastic material layer, 35 pm of an Al metal foil layer disposed over the elastic material layer, and 15 pm of a biaxially oriented nylon-6, 6 sealant material layer disposed over the metal foil layer.
- the listed thicknesses are only exemplary and can instead have other values.
- intermediate layers comprising PSA can be disposed between the individual layers of the flexible packaging material.
- the flexible packaging material may be fabricated by disposing each layer of material over another.
- the flexible packaging material includes an interlaminar adhesive layer.
- the interlaminar adhesive layer is disposed between adjacent layers of the flexible packaging.
- the interlaminar adhesive layer binds the adjacent layers of the flexible packaging together.
- FIG. 5A is an illustration of a process 500A of preparing a flexible packaging material.
- the process 500A begins with an elastic material layer 502A, and in step 504A a metal foil is disposed on the elastic material layer 502A to form a first intermediate assembly 506A.
- a sealant material layer is disposed on the metal foil of the first intermediate assembly 506 A to form the flexible packaging material 510A.
- FIG. 5B is an illustration of a process 500B of preparing a flexible packaging material with interlaminar adhesive layers.
- the process 500B begins with an elastic material layer 502B, and in step 504B a first interlaminar adhesive layer is disposed on the elastic material layer 502B to form a first intermediate assembly 506B.
- a metal foil is disposed on the first interlaminar adhesive layer of the first intermediate assembly 506B to form a second intermediate assembly 510B.
- a second interlaminar adhesive layer is disposed on the metal foil of the second intermediate assembly 510B to form athird intermediate assembly 514B.
- a sealant material is disposed on the second interlaminar adhesive layer of the third intermediate assembly 514B to form the flexible packaging material 518B.
- FIG. 6 is an illustration of an example process 600 for preparing a flexible packaging material, where an initial assembly 602 comprises 75 pm of a polyethylene naphthalate (PEN) carrier film, 100 pm of a BeyolexTM elastic material layer disposed over the carrier film, and 25 pm of a PET cover film disposed over the elastic material.
- the cover film is removed from initial assembly 602 and 35 pm of an Al metal foil layer is disposed over the elastic material layer to form a first intermediate assembly 606.
- 15 pm of a nylon (“ONY”) sealant material layer is disposed over the metal foil layer to form a second intermediate assembly 610. From the second intermediate assembly 610 the carrier film may be removed to form a flexible packaging material, for example the flexible packaging material depicted in FIG. 4.
- PEN polyethylene naphthalate
- BeyolexTM elastic material layer disposed over the carrier film
- 25 pm of a PET cover film disposed over the elastic material.
- the cover film is removed from initial assembly 602 and 35 pm of an Al metal foil layer
- additional elastic polymer layers, additional metal foil layers, additional sealant material layers, and/or intermediate layers may be disposed under, over and/or between the layers during the fabrication of the flexible packaging material.
- a PSA in FIG. 6 prior to disposing 35 pm of an Al metal foil layer over the elastic material layer a PSA may be disposed over the elastic material.
- a PSA in FIG. 6 prior to disposing 15 pm of a nylon (“ONY”) sealant material layer over the 35 pm of an Al metal foil layer a PSA may be disposed over the 15 pm of a nylon (“ONY”) sealant material layer.
- the flexible packaging material may be used to form a flexible packaging encapsulating components of the energy storage device (e.g., separator, electrodes, and electrolyte), thereby forming an energy storage device.
- 1, 2, 3, 4 or 5 flexible packaging materials, or any range of values therebetween, may be used to form a flexible packaging.
- FIG. 7 is an illustration of a process 700 of sealing a cathode, separator and anode assembly within a flexible packaging.
- a first assembly 702 comprising a first flexible packaging material disposed over an anode, separator and cathode assembly, and a second flexible packaging material are provided.
- the first and second flexible packaging materials each comprise an elastic material layer (“Elastic Base - 100 pm”) disposed over an Al metal foil layer (“Al coating - 35 pm”) disposed over a thermal adhesive sealant material layer (“Thermal Adhesive - 15 pm”), wherein the sealant material layers of the first and second flexible packaging materials are adjacent to the anode, separator and cathode assembly.
- heat sealers are provided to the ends of the flexible packaging materials over the elastic material layers to form a second assembly 706, and in step 708 the thermal adhesive sealant material layers of the first and second flexible packaging materials heat sealed together thereby forming a packaging that thereby forms an energy' storage device 710.
- the sides of the packaging material are treated (e.g., corona treated) to improve adhesion and/or the sealing properties of the packaging.
- an electrolyte is introduced to the anode, separator and cathode assembly prior to and/or subsequent to sealing step 708, and therefore the electrolyte is also encapsulated by the packaging.
- the sealing parameters used to seal the flexible packaging material to form the flexible packaging may be useful in forming a suitable seal and/or prevent damage to the flexible packing material or the components of the energy storage device.
- the temperature utilized during sealing is, is about, is at most, or is at most about, 80°C, 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, 160°C, 170°C, 180°C, 190°C, 200°C, 210°C, 220°C, 230°C, 240°C, 250°C or 260°C, or any range of values therebetween.
- the pressure utilized during sealing is, is about, is at most, or is at most about, 10 psi, 20 psi, 25 psi, 30 psi, 35 psi, 40 psi, 45 psi, 50 psi, 55 psi, 60 psi, 70 psi, 80 psi, 90 psi or 100 psi, or any range of values therebetween.
- the sealing is performed for, for about, for at most, or for at most about, 0.5 seconds, 1 second, 2 seconds, 3 seconds, 4 seconds, 5 seconds, 6 seconds, 7 seconds, 8 seconds, 9 seconds, 10 seconds, 11 seconds, 12 seconds, 13 seconds, 14 seconds, 15 seconds, 16 seconds, 17 seconds, 18 seconds or 20 seconds, or any range of values therebetween.
- FIG. 8A is an illustration of a prepared control packaging material
- FIG. 8B is an illustration of a prepared flexible packaging material.
- the control packaging material includes 80 pm of a CPP layer, disposed below 40 pm of an Al foil layer, disposed below 15 pm of an ONY layer, and disposed below 12 pm of a PET layer.
- the flexible packaging material includes 100 pm of a BeyolexTM elastic base material layer, disposed below 50 pm of a PSA layer, disposed below 35-70 pm of an Al coating layer, disposed below 50 pm of a PSA layer, and disposed below 15 pm of a ONY layer.
- FIGS. 8A and 8B Two of each of the control packaging material and the flexible packaging materials depicted in FIGS. 8A and 8B were sealed together similar to the process as depicted in FIG. 7 to form a package encapsulating a graphite anode, an NMC cathode, a separator and an electrolyte comprising LiPFe in EC:EMC, thereby forming a control battery and a flexible test battery.
- the packaging of the flexible test battery is thicker than the control battery, the flexible test battery was found to more easily bend, avoid crinkles when unbent, and have a softer feel.
- FIG. 8C is an illustration of a prepared flexible packaging material.
- the flexible packaging material includes about 92 pm of a BeyolexTM elastic base material layer, disposed on 5-15 pm of PSA as a first interlaminar adhesive layer, disposed on 35 pm of an Al film, disposed on 5-15 pm of PSA as a second interlaminar adhesive layer, and disposed on 60 pm of a PP sealant material layer.
- An “Aluminum Mylar” control battery is manufactured by the same process described with regard to the control battery in Example 1.
- a flexible “Beyolex” test battery is also prepared similar to the process for preparing the flexible test battery as described in Example 1, except the flexible packaging materials used to form the energy storage device each included a Beyolex elastic material mid-layer with a top aluminum foil layer and bottom nylon sealant layer.
- FIG. 9 shows a voltage v. time graph depicting the charge/discharge results of the “Aluminum Mylar” control battery compared to the flexible “Beyolex” test battery. Each battery cell was tap charged until 3.7 V, rested for 12 hours, with charge - discharge cycling performed at C/20 and C/10. As depicted in FIG. 9 the flexible “Beyolex” test battery and the “Aluminum Mylar” control battery demonstrated comparable charge and discharge performances.
- Conditional language such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.
Abstract
A flexible packaging material is described, which includes an elastic material layer, a metal foil layer, and a sealant material layer. The flexible packaging material may also include at least one interlaminar adhesive layer. The flexible packaging material may be utilized to form a packaging encapsulating an energy storage device assembly, thereby forming a flexible energy storage device.
Description
FLEXIBLE PACKAGING FOR USE IN ENERGY STORAGE DEVICES, AND
METHOD OF MANUFACTURE THEREOF
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet or PCT Request as filed with the present application are hereby incorporated by reference under 37 CFR 1.57, and Rules 4.18 and 20.6. The present application claims priority to U.S. Provisional Patent Application No. 63/371,853 filed August 18, 2022, the disclosure of which is incorporated herein by reference in its entirety and for all purposes.
BACKGROUND
Field
[0002] The present disclosure generally relates to energy storage devices, such as batteries: thermoelectric and photoelectric, and supercapacitors. More specifically, the present disclosure relates to energy storage devices (e.g., electrochemical devices) with flexible packaging.
Description of the Related Art
[0003] Energy storage devices include batteries, fuel cells, electrochemical sensors (e.g., glucose monitors) and bio-fuel cells. Typical existing energy storage devices (e.g., batteries) may be deficient with regard to several aspects, for example with regard to charge/discharge rates, total energy, power performance, and the rigidity of the energy storage device itself.
[0004] Flexible energy storage devices require each component (e.g., separator, electrodes, packaging, and electrolyte) to be durable and flexible without compromising the integrity and performance of the device. Traditional packaging may typically be formed from multilayer materials that can be sealed to form a pouch that will contain the other components of the energy storage device (e.g., separator, electrodes, and electrolyte). However, typical packaging does not meet emerging requirements for flexible energy storage devices. Therefore, there is a need for improved packaging for flexible energy storage devices.
SUMMARY
[0005] For purposes of summarizing the disclosure and the advantages achieved over the prior art, certain objects and advantages of the disclosure are described herein. Not all such objects or advantages may be achieved in any particular embodiment. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.
[0006] In one aspect, a flexible packaging material is described. The flexible packaging material includes an elastic material layer; a metal foil layer; and a sealant material layer.
[0007] In one aspect, a flexible packaging material is described. The flexible packaging material includes an elastic material layer; a metal foil layer; and a sealant material layer; wherein the metal foil layer is disposed between the elastic material layer and the sealant material layer.
[0008] In some embodiments, the elastic material layer compnses a material selected from the group consisting of a thermoplastic material, a thermoset material, and combinations thereof. In some embodiments, the elastic material layer comprises a polymer selected from the group consisting of a styrene polymer, an isoprene polymer, an ethylene polymer, a propylene polymer, a butadiene polymer, a butylene polymer, a diene polymer, a polyurethane polymer, an acetate polymer, copolymers thereof, and mixtures thereof. In some embodiments, the elastic material layer comprises a thickness of about 50-100 pm.
[0009] In some embodiments, the metal foil layer comprises Al. In some embodiments, the metal foil layer comprises a thickness of about 20-60 pm. In some embodiments, the sealant material layer comprises a material selected from the group consisting of nylon (ONY), a polypropylene (PP) resin, an ethylene and acrylic acid (EAA) a copolymer resin, copolymers thereof, orientations thereof, and mixtures thereof. In some embodiments, the sealant material layer comprises a thickness of about 30-100 pm.
[0010] In some embodiments, the flexible packaging material further comprises at least one interlaminar adhesive layer. In some embodiments, a position of the at least one interlaminar adhesive layer is selected from the group consisting of disposed between the elastic material layer and the metal foil layer, disposed between the metal foil layer and the sealant material layer, and combinations thereof. In some embodiments, the at least
one interlaminar adhesive layer comprises a material selected from the group consisting of a urethane adhesive, an acrylic adhesive, a polyolefin adhesive, and combinations thereof. In some embodiments, the at least one interlaminar adhesive layer comprises a thickness of about 5-15 pm.
[0011] In another aspect, a flexible energy storage device is described. The flexible energy storage device includes a flexible packaging material; a cathode; an anode; and a separator disposed between the another and the cathode.
[0012] In some embodiments, the flexible energy storage device further comprises an electrolyte. In some embodiments, wherein at least one of the cathode and the anode comprises an electron beam cured polymer binder.
[0013] In another aspect, a method of forming a flexible energy storage device is described. The method includes disposing an energy storage device assembly between a top packaging material and a bottom packaging material, wherein the top and bottom packaging materials each comprise a flexible packaging material; sealing the top and bottom packaging materials to form a sealed packaging, wherein the energy storage device assembly and the sealed packaging form the flexible energy storage device.
[0014] In some embodiments, sealing comprises a sealing temperature of about 130-210°C. In some embodiments, sealing comprises a sealing pressure of about 25-60 psi. In some embodiments, sealing comprises a sealing time of about 2-10 second.
[0015] In another aspect, a method of forming a flexible packaging material is described. The method includes disposing a metal foil layer over an elastic material layer; and disposing a sealant material layer over the metal foil layer.
[0016] In some embodiments, the method further comprises disposing a first interlaminar adhesive layer over the elastic material layer, and disposing the metal foil layer over the first interlaminar adhesive layer. In some embodiments, the method further comprises disposing a second interlaminar adhesive layer over the metal foil layer, and disposing the sealant material layer over the second interlaminar adhesive layer.
[0017] All of these embodiments are intended to be within the scope of the invention herein disclosed. These and other embodiments will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular preferred embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is an illustration of a cathode, separator and anode assembly, according to some embodiments.
[0019] FIG. 2 is an illustration of an energy storage device, according to some embodiments.
[0020] FIG. 3A is an illustration of a flexible packaging material, according to some embodiments.
[0021] FIG. 3B is an illustration of a flexible packaging material with interlaminar adhesive layers, according to some embodiments.
[0022] FIG. 4 is an illustration of a flexible packaging material, according to some embodiments.
[0023] FIG. 5A is an illustration of a process of preparing a flexible packaging material, according to some embodiments.
[0024] FIG. 5B is an illustration of a process of preparing a flexible packaging material with interlaminar adhesive layers, according to some embodiments.
[0025] FIG. 6 is an illustration of a process of preparing a flexible packaging material, according to some embodiments.
[0026] FIG. 7 is an illustration of a process of sealing a cathode, separator and anode assembly within a flexible packaging, according to some embodiments.
[0027] FIG. 8A is an illustration of a control packaging material used to form a packaging of an energy' storage device.
[0028] FIG. 8B is an illustration of a flexible packaging material used to form a packaging of a flexible energy storage device, according to some embodiments.
[0029] FIG. 8C is an illustration of a flexible packaging material used to form a packaging of a flexible energy storage device, according to some embodiments.
[0030] FIG. 9 shows a voltage v. time graph depicting the charge/discharge results of a control energy storage device and a flexible energy storage device, according to some embodiments.
DETAILED DESCRIPTION
[0031] Although certain embodiments and examples are described below, those of skill in the art will appreciate that the invention extends beyond the specifically disclosed embodiments and/or uses and obvious modifications and equivalents thereof. Thus, it is
intended that the scope of the invention herein disclosed should not be limited by any particular embodiments described below.
[0032] In this disclosure, an improved flexible packaging material for energy storage device packaging is disclosed. In some embodiments, the flexible packaging material comprises multiple layers of materials. For example, in certain embodiments, the multiple layers include an elastic material layer used as a base material, a metal foil layer and a sealant material layer, to build a robust, impermeable dielectric film for the energy storage device (e.g., battery) packaging. In some embodiments, the use of an elastic material layer allows for the formation of a flexible packaging with improved flexibility, durability, confonnability, and/or stretchability, while simultaneously sealing the other components of the energy storage device (e.g., separator, electrodes, and electrolyte) within the packaging. In some embodiments, the flexible packaging formed from the flexible packaging material is or is substantially impermeable water and air, and resistant to degradation due to the operation of the energy storage device itself and/or electrolyte contained within.
[0033] In some embodiments, the energy' storage (e.g., electrochemical) device may include a battery. In some embodiments, the energy storage (e.g., electrochemical) device may include fuel cells, electrochemical sensors (glucose monitors), bio-fuel cells, and combinations thereof. In some embodiments, the disclosed energy storage device (e.g., battery) may be a solid-state energy storage device.
Energy Storage Device
[0034] FIG. 1 illustrates an assembly 100 comprising a cathode 102, a separator 104, and an anode 106. The electrodes (i.e., cathode 102 and anode 106) each comprise an electrode film disposed over a current collector. The electrode films comprise an active material and a binder, and may further comprise additional elements such as a conductive additive. As depicted in FIG. 1, the electrode film of the anode 106 includes active material particles, a binder, and conductive additive particles and/or nanostructures in certain embodiments.
[0035] FIG. 2 is an illustration of an assembled die cut shaped energy storage device 200. The energy storage device 200 includes an anode 202 and a cathode 206 separated by a separator 204, which is encased in a packaging 210. The anode 202 is in electrical contact with a current collector 208A, and the cathode 206 is in electrical contact with a current collector 208B. In the illustrated embodiment, the components of the energy
storage device 200 are shown disposed over a substrate 212. In some embodiments, the energy storage device 200 further includes anode and cathode electrical connectors (e.g., leads and/or tabs) from the anode and cathode cunent collectors 208 A, 208B, respectively, coming out of the sealed film and/or are exposed in order for the energy storage device 200 to make electrical connections with a device in need thereof. In some embodiments, the substrate 212 also comprises a material the same, substantially the same or similar to the material of the packaging 210, such that the packaging 210 and substrate 212 form a seal and encapsulate the anode 202, cathode 206 and separator 204 to form a water-impermeable and/or oxygen-impermeable packaging. For example, in some embodiments the packaging 210 and substrate 212 each are or comprise a flexible packaging material described herein.
[0036] The energy storage device 200 can be a primary or rechargeable energy storage device, and in various forms. Prior to assembly and sealing the cell of the energy storage device 200, the device 200 may be filled with an electrolyte. In some embodiments, the energy storage device 200 is a battery, a capacitor, or a combination thereof. In some embodiments, the energy storage device 200 is a solid state energy' storage device such that the energy storage device 200 includes a solid state electrolyte positioned between the cathode 206 and the anode 202. In some embodiments, the solid state electrolyte is in a semisolid (e.g., gel) or solid form.
[0037] The energy storage device 200 can include a first electrode 202, 206 that includes a first current collector 208 A, 208B in contact with a first electrode film (e.g., a cathode electrode with a cathode electrode film), and a second electrode 202, 206 that includes a second current collector 208A, 208B in contact with a second electrode film (e.g., an anode electrode with an anode electrode film). The first current collector 208A, 208B and the second current collector 208A, 208B may facilitate electrical coupling between each corresponding electrode film and an external circuit (not shown). For example, the current collector 208A, 208B (i.e., base layer) can include a metallic material, such as a material comprising aluminum, nickel, copper, rhenium, niobium, tantalum, and noble metals such as silver, gold, platinum, palladium, rhodium, osmium, iridium and alloys and combinations of the foregoing. For example, the current collector 208A, 208B can comprise a metal foil, for example, a nickel foil, an aluminum foil, a carbon foil, a copper foil, a carbon coated metal foil, or a tantalum coated metal foil. In some embodiments, the current collector 208A, 208B (i.e., base layer) may include copper, aluminum, and coated metal foils, and combinations thereof. The electrode 202, 206 can include at least one electrode film on or disposed over a surface of the current collector
208A, 208B. In some embodiments, the electrode 202, 206 may be a multilayer electrode and comprise more than one electrode film, for example, such as a first electrode film and a second electrode film disposed on the same or different sides of the current collector 208A, 208B. In some embodiments, the multilayered electrode is heterogeneous such that the properties, loading, thickness and/or composition of a first electrode film is different than that of a second electrode film of the electrode.
[0038] The electrode film may comprise a cathode active material or an anode active material. In some embodiments, the electrode film and/or electrode film mixture comprises the active material in, in about, in at least, or in at least about, 60 wt.%, 65 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 90 wt.%, 92 wt.%, 95 wt.%, 97 wt.%, 98 wt.% or 99 wt.%, or any range of values therebetween.
[0039] The cathode active material can include, for example, carbon monofluoride (CFx), metal oxide, metal sulfide, or a lithium metal oxide. The lithium metal oxide can be, for example, a lithium nickel manganese cobalt oxide (NMC), a lithium manganese oxide (LMO), a lithium iron phosphate (LFP), a lithium cobalt oxide (LCO), a lithium titanate (LTO), and/or a lithium nickel cobalt aluminum oxide (NCA). In some embodiments, cathode active materials can comprise, for example, a layered transition metal oxide (such as LiCoCh (LCO), Li(NiMnCo)O2 (NMC) and/or LiNi0.8Co0.15Al0.05O2 (NCA)), a spinel manganese oxide (such as LiMn2O4 (LMO) and/or LiMm.5Nio.5O4 (LMNO)), an olivine (such as LiFePO4), chalcogenides (LiTiS2), tavorite (LiFeSO4F), silicon, silicon oxide (SiOx), aluminum, tin, tin oxide (SnOx), manganese oxide (MnOx), molybdenum oxide (MOO2), molybdenum disulfide (M0S2), nickel oxide (NiOx), or copper oxide (CuOx). The anode active materials can include, for example, an insertion material (such as carbon, graphite (natural, synthetic or blends), hard or amorphous carbons and/or graphene), an alloy ing/dealloying material (such as silicon, silicon oxide, tin, and/or tin oxide), a metallic element, metal alloy or compound (such as Si-Al, and/or Si-Sn), and/or a conversion material (such as manganese oxide, molybdenum oxide, nickel oxide, and/or copper oxide). The anode active materials can be used alone or mixed together to form multi-phase materials (such as Si-C, Sn-C, SiOx-C, SnOx-C, Si-Sn, Si-SiOx, Sn-SnOx, Si- SiOx-C, Sn-SnOx-C, Si-Sn-C, SiOx-SnOx-C, Si-SiOx-Sn, or Sn-SiOx-SnOx ).
[0040] In some embodiments, the electrode film and/or electrode film mixture can comprise a binder. In some embodiments, the electrode film comprises the binder in, in about, in at most, in at most about, 0.5 wt.%, 1 wt.%, 2 wt.%, 3 wt.%. 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt.%, or any range of
values therebetween. In some embodiments, the binder is a polymerizable binder. In some embodiments, the polymerizable binder is electron beam (“e-beam” or “EB”) polymerizable and/or curable. Binders may include an acrylated polyurethane resin (e.g. Ucecoat 7689, Ucecoat 7510, and Ucecoat 7690 (i.e. a polyurethane acrylate, acry late ester and/or acrylated monomer dispersion in water)), a hydroxy modified acrylated polyurethane resin (e g., hydroxy modified Ucecoat 7690), an acrylate-methacrylate monomer blend (e.g. Ebecryl 109), a monoacrylate of mono-ethoxylated phenol (e.g. Ebecryl 114), trimethylolpropane ethoxy triacrylate (TMPEOTA), an acrylonitrile and/or acrylamide (e.g., LA133), polytetrafluoroethylene (PTFE), a polyolefin, polyalkylenes, polyethers, styrene-butadiene, co-polymers of polysiloxanes, a polysiloxane, branched polyethers, polyvinylethers, polyacrylic acid (PAA), styrene-butadiene rubber (SBR), copolymers thereof, and/or admixtures thereof. The binder can include a cellulose, for example, carboxymethylcellulose (CMC). In some embodiments, the polyolefin can include polyethylene (PE), polypropylene (PP), polyvinylidene fluoride (PVDF), copolymers thereof, and/or mixtures thereof. For example, the binder can include polyvinylene chloride, poly(phenylene oxide) (PPO), polyethylene-block-poly(ethylene glycol), poly(ethylene oxide) (PEO), poly(phenylene oxide) (PPO), polyethylene-block- poly(ethylene glycol), polydimethylsiloxane (PDMS), polydimethylsiloxanecoalkylmethylsiloxane, co-polymers thereof, and/or admixtures thereof. In some embodiments, the binder may include an acrylated polyurethane resin, an acrylatemethacrylate monomer blend, a monoacrylate of mono-ethoxylated phenol, polyvinylidene fluoride (PVDF), and combinations thereof. In some embodiments, the binder may include an acrylated polyurethane resin, an acrylate-methacrylate monomer blend, a monoacrylate of mono-ethoxylated phenol, and combinations thereof.
[0041] In some embodiments, the electrode film and/or electrode film mixture can comprise an additive. In some embodiments, the electrode film and/or electrode film mixture comprises the additive in, in about, in at most, in at most about, 0.05 wt.%, 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1 wt.%, 1.5 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.%, 10 wt.%, 15 wt.%, 20 wt.% or 25 wt.%, or any range of values therebetween. In some embodiments, the additive is a conductive additive, a rheological additive, an etching additive, or combinations thereof. In some embodiments, the additive is a conductive additive. In some embodiments, conductive additives may be selected from carbon black, carbon nanoparticles, a graphitic material, graphite, graphene-containing materials, hard carbon, soft
carbon, carbon nanotubes, carbon nanofibers, porous carbon, conductive carbon, a high- aspect ratio conductive additive or a combination thereof. In some embodiments, the graphitic material can be a surface treated material. In some embodiments, the porous carbon can comprise activated carbon. In some embodiments, the porous carbon can comprise hierarchically structured carbon. In some embodiments, the porous carbon can include structured carbon nanotubes, structured carbon nano wires and/or structured carbon nanosheets. In some embodiments, the porous carbon can include graphene sheets. In some embodiments, the porous carbon can be a surface treated carbon. In some embodiments, the high-aspect ratio conductive additive is selected from a carbon nanofiber, a carbon nanotube, a chopped carbon nanofiber, a nanowire, a chopped metal thread, and combinations thereof. In some embodiments, the chopped metal thread comprises a metal nickel, copper, silver, and combinations thereof. The high aspect ratio fibers allow the battery electrodes to maintain electrical contact during the deformation. In some embodiments, the additive is a rheological additive. In some embodiments, a rheological additive includes oxalic acid. In some embodiments, the additive is an etching additive. In some embodiments, the etching additive is added to the electrode film mixture and/or to the current collector to remove or reduce the oxidation layer of a current collector once applied, thereby allowing the electrode film to strongly adhere to the current collector (e.g., resulting in improved electrical conductivity and battery performance). In some embodiments, an etching additive includes oxalic acid, nitric acid, HC1, or combinations thereof.
[0042] In some embodiments, the electrode film may comprise a surfactant. In some embodiments, the surfactant is selected from a hydrocarbon surfactant, a fluoro surfactant, a silicon surfactant, a polyoxypropylene surfactant, and combinations thereof. In some embodiments, the surfactant is selected from an amphiphilic surfactant, a cationic surfactant, an anionic surfactant, a non-ionic surfactant, a polymeric surfactant, a biosurfactant, and combinations thereof. In some embodiments, surfactants include polyethylene glycol derivatives (e g., Triton X-100
) (molecular weight 695 g/mol to 1,000.000 g/mol)), polyvinylpyrrolidone (PVP), cationic poly(ethyleneimine) (PEI, molecular weight 10,000 g/mol to 1,000.000 g/mol), and anionic poly(acrylic acid) (PAA, molecular weight 15,000 g/mol to 1,000.000 g/mol). In some embodiments, surfactant provides properties such as reduced surface tension and energy,
emulsifi cation, dispersion and solubilization for casting and/or dry ing of the electrode film. In some embodiments, surfactants include structure-directing agents, carbon sources, porogen agents and stabilizer agents. In some embodiments, the surfactant includes a molecular weight of, of about, of at most, or of at most about, 300 g/mol, 500 g/mol, 600 g/mol, 700 g/mol, 800 g/mol, 1,000 g/mol, 2,000 g/mol, 5,000 g/mol, 10,000 g/mol, 15,000 g/mol, 20,000 g/mol, 30,000 g/mol, 40,000 g/mol, 50,000 g/mol, 60,000 g/mol or 80,000 g/mol, or any range of values therebetween. In some embodiments the electrode film and/or electrode film mixture comprises the surfactant in, in about, in at most, in at most about, 0.001 wt.%, 0.005 wt.%, 0.01 wt.%, 0.02 wt.%, 0.03 wt.%, 0.04 wt.%, 0.05 wt.%, 0.06 wt.%, 0.07 wt.%, 0.08 wt.%, 0.09 wt.%, 0.1 wt.%, 0.2 wt.%, 0.3 wt.%, 0.4 wt.%, 0.5 wt.%, 0.6 wt.%, 0.7 wt.%, 0.8 wt.%, 0.9 wt.%, 1 wt.%, 2 wt.%, 3 wt.%, 4 wt.%, 5 wt.%, 6 wt.%, 7 wt.%, 8 wt.%, 9 wt.% or 10 wt.%, or any range of values therebetween.
[0043] The energy storage device 200 can include any number of different types of electrolyte. For example, in some embodiments, the device 200 can include a lithium ion battery electrolyte, which can include a lithium source, such as a lithium salt, and a solvent, such as an organic solvent. In some embodiments, the device can further include an electrolyte additive, such as solid electrolyte interphase (SEI)-forming additive, an electrode wetting additive, or a separator wetting additive. In some embodiments, a lithium salt can include lithium hexafluorophosphate (LiPFe), lithium tetrafluoroborate (LiBF4), lithium perchlorate (LiC'IOi). lithium bis(trifluoromethansulfonyl)imide (LiNCSChCFg lithium trifluoromethansulfonate (LiSOsCFs), lithium bis(pentafluoroethanesulfonyl)imide (C4FioLiN04S2), lithium bis(fluorosulfonyl)imide (F2LiNO4S2), lithium bis(oxalato)borate (LiB(C2<)4)2), lithium difluoro(oxalato) borate (LiBF2(C2C>4), lithium difluorophosphate (FgLiChP), lithium oxalyldifluoroborate, lithium trifluorochloroborate (LiBFsCl), lithium hexafluoroarsenate (LiAsFs), lithium bis(trifluoromethanesulfonyl)imide (LiTFSi), combinations thereof, and/or the like. In some embodiments, a lithium ion electrolyte solvent can include one or more ethers and/or esters. For example, a lithium ion electrolyte solvent may comprise ethylene carbonate (EC), dimethyl carbonate (DMC), diethyl carbonate (DEC), ethyl methyl carbonate (EMC), vinyl carbonate (VC), propylene carbonate (PC), fluoroethylene carbonate (FEC), 1,3-propane sultone (PS), combinations thereof, and/or the like. For example, the electrolyte may comprise LiPFe, ethylene carbonate, propylene carbonate and diethyl carbonate. In some embodiments, the device can include a solid state electrolyte. In some embodiments, the solid state electrolyte also functions as a separator.
[0044] Electrodes described herein may be prepared by various processes. As one example, in some embodiments an electrode film mixture (e.g. comprising the active material, binder, and optionally additives) are combined with a solvent to form an electrode film slurry. In some embodiments, the solvent is an aqueous solvent, an organic solvent, or a combination thereof. As another example, in some embodiments an electrode film mixture (e.g. comprising the active material, binder, and optionally additives) is combined and an electrode film is formed in a solvent-free dry electrode manufacturing process. In some embodiments, the electrode film mixture further comprises a surfactant and/or an additive (e.g. a conductive additive, a rheological additive, and/or an etching agent). In some embodiments, the solvent includes water, N-methylpyrrolidone (NMP), other organic solvents, or combinations thereof. The electrode film slurry may then be cast upon a substrate to form an as-cast electrode film. In some embodiments, casting of the electrode film slurry may be performed using a doctor blade, spray coating, comma bar, slot die, aerosol, gravure, screen printing, imprinting, spin-coating, electrospinning, ultrasonic spray, electrostatic spray, and combinations thereof. The as-cast electrode film may then be dried and/or cured to form an electrode film. In some embodiments, the as-cast electrode film or electrode film is calendered (e.g. a roll-to-roll process). In some embodiments, the as-cast electrode film or electrode film is not calendered. In solvent-free dry electrode manufacturing processes the electrode film may be formed using dry materials, such as a calendering process. In some embodiments, the substrate which the dry electrode film or electrode film slurry is cast upon is a current collector, and as such an electrode is formed once the electrode film is deposited, dried and/or cured.
[0045] Drying may be performed by heating (e.g., vacuum heating and/or convection heating) the as-cast electrode film to evaporate the solvent. Curing may be performed to polymerize the binder to form a binder matrix within the electrode film. In some embodiments, curing is performed by an energy source, such as for example photons and/or electrons. In some embodiments, curing is performed by an electron beam (“e- beam” or “EB”). In some embodiments, the curing is performed with an EB with, with about, with at least, or with at least about, 50 kV, 100 kV, 150 kV, 200 kV, 250 kV 300 kV, or any range of values therebetween. In some embodiments, the curing is performed with an EB with, with about, with at least, or with at least about, 15 kGy, 20 kGy, 25 kGy, 30 kGy, 40 kGy, 50 kGy, 60 kGy, 70 kGy, 80 kGy or 100 kGy, or any range of values therebetween.
Flexible Packaging Material
[0046] In some embodiments, the flexible packaging material comprises an elastic material layer, a metal foil layer and a sealant material layer. In some embodiments, the elastic material layer comprises an elastic polymer. In some embodiments, the elastic material layer comprises a thermoplastic material, a thermoset material, or combinations thereof. In some embodiments, the elastic polymer comprises a thermoplastic polymer, a thermoset polymer, or combinations thereof. In some embodiments, the elastic polymer comprises a styrene polymer, an isoprene polymer, an ethylene polymer, a propylene polymer, a butadiene polymer, a butylene polymer, a diene polymer, a polyurethane polymer, an acetate polymer (e.g., vinyl acetate), copolymers thereof (e.g., block copolymers, for example such as A-B or A-B-A block copolymers), and mixtures thereof. For example, the elastic material layer may comprise or consist of a thermoset material (e.g., Panasonic Beyolex™). In some embodiments, the elastic material layer is, is about, is at least, or is at least about, 10 pm, 20 pm, 30 pm, 40 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 110 pm, 120 pm, 130 pm, 140 pm, 150 pm, 160 pm, 170 pm, 180 pm, 190 pm or 200 pm, or any range of values therebetween. In some embodiments, the flexible packaging material comprises, or comprises at least, 1, 2, 3, 4 or 5 layers, or any range of values therebetween, of the elastic material layer.
[0047] In some embodiments, the metal foil layer is impermeable or substantially impermeable to oxygen and/or water. In some embodiments, the metal foil layer comprises aluminum. In some embodiments, the metal foil layer comprises an aluminum (“Al”) foil or coating. In some embodiments, the metal foil layer is coated on and/or disposed over the elastic material layer. In some embodiments, the metal foil layer comprises at least one surface that is surface treated. In some embodiments, the metal foil layer is, is about, is at least, or is at least about, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm or 100 pm, or any range of values therebetween. In some embodiments, the flexible packaging material comprises, or comprises at least, 1, 2, 3, 4 or 5 layers, or any range of values therebetween, of the metal foil layer.
[0048] In some embodiments, the sealant material layer may be used to seal the flexible packaging material to form a packaging, for example by sealing together the sealant materials layers from two or more flexible packaging materials. In some embodiments, the sealant material layer is impermeable or substantially impermeable to oxygen and/or water. In some embodiments, the sealant material layer comprises a sealant material. In some
embodiments, the sealant material comprises a thermal adhesive. In some embodiments, the sealant material comprises nylon (“ONY”), a polypropylene (PP) resin (e.g., cast polypropylene (CPP), blown polypropylene (BPP) and other variants), an ethylene and acrylic acid (EAA) copolymer resin, copolymers thereof, orientations thereof (e.g., bi- axially oriented), and/or mixtures thereof. In some embodiments, the sealant material is, is about, is at least, or is at least about, 3 pm, 5 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm, 100 pm, 110 pm, 120 pm, 130 pm, 140 pm, 150 pm or 200 pm, or any range of values therebetween. In some embodiments, the flexible packaging material comprises, or comprises at least, 1, 2, 3, 4 or 5 layers, or any range of values therebetween, of the sealant material layer.
[0049] In some embodiments, the flexible packaging material may comprise at least one intermediate or interlaminar layer. In some embodiments, the intermediate or interlaminar layer may comprise a material selected from polyethylene terephthalate (“PET”), an adhesive (e.g., a pressure sensitive adhesive (“PSA”)), a polypropylene (e.g., a polypropylene (“PP”) film), and combinations thereof. In some embodiments, the PSA is selected from a urethane adhesive (e.g., Loctite Liofol LA 3649 adhesive and LA 6255 curing agent), an acrylic adhesive, a polyolefin adhesive, and combinations thereof. In some embodiments, the intermediate or interlaminar layer is, is about, is at least, or is at least about, 1 pm, 2 pm, 3 pm, 4 pm, 5 pm, 6 pm, 7 pm, 8 pm, 9 pm, 10 pm, 15 pm, 20 pm, 25 pm, 30 pm, 35 pm, 40 pm, 45 pm, 50 pm, 60 pm, 70 pm, 80 pm, 90 pm or 100 pm, or any range of values therebetween. In some embodiments, the flexible packaging material comprises, or comprises at least, 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 layers, or any range of values therebetween, of the intermediate or interlaminar layer.
[0050] In some embodiments, one or more layers of the flexible packaging material (e.g., elastic material layer, metal foil layer, sealant material layer, intermediate layer) may be treated. In some embodiments, the treatment is a chemical treatment, surface treatment, or combinations thereof. In some embodiments, the treatment may include a corona treatment. In some embodiments, the treatment may improve adhesion between surfaces of adjacent layers.
[0051] FIG. 3A is an illustration of a flexible packaging material, wherein the flexible packaging material comprises an elastic material layer, a metal foil layer disposed over the elastic material layer, and a sealant material layer disposed over the metal foil layer. FIG. 3B is an illustration of a flexible packaging material with interlaminar adhesive layers, wherein the flexible packaging material comprises an elastic material layer, a first
interlaminar adhesive layer disposed over the elastic material layer, a metal foil layer disposed over the first interlaminar adhesive layer, a second interlaminar adhesive layer disposed over the metal foil layer, and a sealant material layer disposed over the second interlaminar adhesive layer.
[0052] FIG. 4 is an illustration of an example flexible packaging material. In certain embodiments, the flexible packaging material comprises an elastic material layer, an Al metal foil layer disposed over the elastic material layer, and a biaxially oriented nylon-6, 6 sealant material layer disposed over the metal foil layer. For example, in the illustrated embodiment, the flexible packaging material comprises 100 pm of a Beyolex™ elastic material layer, 35 pm of an Al metal foil layer disposed over the elastic material layer, and 15 pm of a biaxially oriented nylon-6, 6 sealant material layer disposed over the metal foil layer. Of course, the listed thicknesses are only exemplary and can instead have other values. Although not depicted in FIG. 4, intermediate layers comprising PSA can be disposed between the individual layers of the flexible packaging material.
Method of Fabricating Flexible Packaging Material
[0053] The flexible packaging material may be fabricated by disposing each layer of material over another. In some embodiments, the flexible packaging material includes an interlaminar adhesive layer. In some embodiments, the interlaminar adhesive layer is disposed between adjacent layers of the flexible packaging. For example, in certain embodiments, the interlaminar adhesive layer binds the adjacent layers of the flexible packaging together.
[0054] FIG. 5A is an illustration of a process 500A of preparing a flexible packaging material. The process 500A begins with an elastic material layer 502A, and in step 504A a metal foil is disposed on the elastic material layer 502A to form a first intermediate assembly 506A. In step 508A, a sealant material layer is disposed on the metal foil of the first intermediate assembly 506 A to form the flexible packaging material 510A.
[0055] FIG. 5B is an illustration of a process 500B of preparing a flexible packaging material with interlaminar adhesive layers. The process 500B begins with an elastic material layer 502B, and in step 504B a first interlaminar adhesive layer is disposed on the elastic material layer 502B to form a first intermediate assembly 506B. In step 508B, a metal foil is disposed on the first interlaminar adhesive layer of the first intermediate assembly 506B to form a second intermediate assembly 510B. In step 512B, a second interlaminar adhesive layer is disposed on the metal foil of the second intermediate
assembly 510B to form athird intermediate assembly 514B. In step 516B, a sealant material is disposed on the second interlaminar adhesive layer of the third intermediate assembly 514B to form the flexible packaging material 518B.
[0056] FIG. 6 is an illustration of an example process 600 for preparing a flexible packaging material, where an initial assembly 602 comprises 75 pm of a polyethylene naphthalate (PEN) carrier film, 100 pm of a Beyolex™ elastic material layer disposed over the carrier film, and 25 pm of a PET cover film disposed over the elastic material. In step 604, the cover film is removed from initial assembly 602 and 35 pm of an Al metal foil layer is disposed over the elastic material layer to form a first intermediate assembly 606. In step 608, 15 pm of a nylon (“ONY”) sealant material layer is disposed over the metal foil layer to form a second intermediate assembly 610. From the second intermediate assembly 610 the carrier film may be removed to form a flexible packaging material, for example the flexible packaging material depicted in FIG. 4.
[0057] In some embodiments, additional elastic polymer layers, additional metal foil layers, additional sealant material layers, and/or intermediate layers may be disposed under, over and/or between the layers during the fabrication of the flexible packaging material. For example, in some embodiments, in FIG. 6 prior to disposing 35 pm of an Al metal foil layer over the elastic material layer a PSA may be disposed over the elastic material. As a further example, in some embodiments, in FIG. 6 prior to disposing 15 pm of a nylon (“ONY”) sealant material layer over the 35 pm of an Al metal foil layer a PSA may be disposed over the 15 pm of a nylon (“ONY”) sealant material layer.
Method of Using Flexible Packaging Material
[0058] The flexible packaging material may be used to form a flexible packaging encapsulating components of the energy storage device (e.g., separator, electrodes, and electrolyte), thereby forming an energy storage device. In some embodiments, 1, 2, 3, 4 or 5 flexible packaging materials, or any range of values therebetween, may be used to form a flexible packaging. FIG. 7 is an illustration of a process 700 of sealing a cathode, separator and anode assembly within a flexible packaging. A first assembly 702 comprising a first flexible packaging material disposed over an anode, separator and cathode assembly, and a second flexible packaging material are provided. The first and second flexible packaging materials each comprise an elastic material layer (“Elastic Base - 100 pm”) disposed over an Al metal foil layer (“Al coating - 35 pm”) disposed over a thermal adhesive sealant material layer (“Thermal Adhesive - 15 pm”),
wherein the sealant material layers of the first and second flexible packaging materials are adjacent to the anode, separator and cathode assembly. In step 704, heat sealers are provided to the ends of the flexible packaging materials over the elastic material layers to form a second assembly 706, and in step 708 the thermal adhesive sealant material layers of the first and second flexible packaging materials heat sealed together thereby forming a packaging that thereby forms an energy' storage device 710. In some embodiments, the sides of the packaging material are treated (e.g., corona treated) to improve adhesion and/or the sealing properties of the packaging. In some embodiments, an electrolyte is introduced to the anode, separator and cathode assembly prior to and/or subsequent to sealing step 708, and therefore the electrolyte is also encapsulated by the packaging.
[0059] The sealing parameters used to seal the flexible packaging material to form the flexible packaging may be useful in forming a suitable seal and/or prevent damage to the flexible packing material or the components of the energy storage device. In some embodiments, the temperature utilized during sealing is, is about, is at most, or is at most about, 80°C, 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, 160°C, 170°C, 180°C, 190°C, 200°C, 210°C, 220°C, 230°C, 240°C, 250°C or 260°C, or any range of values therebetween. In some embodiments, the pressure utilized during sealing is, is about, is at most, or is at most about, 10 psi, 20 psi, 25 psi, 30 psi, 35 psi, 40 psi, 45 psi, 50 psi, 55 psi, 60 psi, 70 psi, 80 psi, 90 psi or 100 psi, or any range of values therebetween. In some embodiments, the sealing is performed for, for about, for at most, or for at most about, 0.5 seconds, 1 second, 2 seconds, 3 seconds, 4 seconds, 5 seconds, 6 seconds, 7 seconds, 8 seconds, 9 seconds, 10 seconds, 11 seconds, 12 seconds, 13 seconds, 14 seconds, 15 seconds, 16 seconds, 17 seconds, 18 seconds or 20 seconds, or any range of values therebetween.
EXAMPLES
Example 1
[0060] FIG. 8A is an illustration of a prepared control packaging material, and FIG. 8B is an illustration of a prepared flexible packaging material. In certain embodiments, the control packaging material includes 80 pm of a CPP layer, disposed below 40 pm of an Al foil layer, disposed below 15 pm of an ONY layer, and disposed below 12 pm of a PET layer. In certain embodiments, the flexible packaging material includes 100 pm of a Beyolex™ elastic base material layer, disposed below 50 pm of a
PSA layer, disposed below 35-70 pm of an Al coating layer, disposed below 50 pm of a PSA layer, and disposed below 15 pm of a ONY layer.
[0061] Two of each of the control packaging material and the flexible packaging materials depicted in FIGS. 8A and 8B were sealed together similar to the process as depicted in FIG. 7 to form a package encapsulating a graphite anode, an NMC cathode, a separator and an electrolyte comprising LiPFe in EC:EMC, thereby forming a control battery and a flexible test battery. Although the packaging of the flexible test battery is thicker than the control battery, the flexible test battery was found to more easily bend, avoid crinkles when unbent, and have a softer feel.
Example 2
[0062] FIG. 8C is an illustration of a prepared flexible packaging material. The flexible packaging material includes about 92 pm of a Beyolex™ elastic base material layer, disposed on 5-15 pm of PSA as a first interlaminar adhesive layer, disposed on 35 pm of an Al film, disposed on 5-15 pm of PSA as a second interlaminar adhesive layer, and disposed on 60 pm of a PP sealant material layer.
Example 3
[0063] An “Aluminum Mylar” control battery is manufactured by the same process described with regard to the control battery in Example 1. A flexible “Beyolex” test battery is also prepared similar to the process for preparing the flexible test battery as described in Example 1, except the flexible packaging materials used to form the energy storage device each included a Beyolex elastic material mid-layer with a top aluminum foil layer and bottom nylon sealant layer.
[0064] FIG. 9 shows a voltage v. time graph depicting the charge/discharge results of the “Aluminum Mylar” control battery compared to the flexible “Beyolex” test battery. Each battery cell was tap charged until 3.7 V, rested for 12 hours, with charge - discharge cycling performed at C/20 and C/10. As depicted in FIG. 9 the flexible “Beyolex” test battery and the “Aluminum Mylar” control battery demonstrated comparable charge and discharge performances.
[0065] While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the
systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.
[0066] Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[0067] Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.
[0068] Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional
embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. For example, any of the components for an energy storage system described herein can be provided separately, or integrated together (e.g., packaged together, or atached together) to form an energy storage system.
[0069] For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
[0070] Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.
[0071] Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.
[0072] Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or charactenstic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount, depending on the desired function or desired result.
[0073] The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.
[0074] The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.
Claims
1. A flexible packaging material, comprising: an elastic material layer; a metal foil layer; and a sealant material layer; wherein the metal foil layer is disposed between the elastic material layer and the sealant material layer.
2. The flexible packaging material of Claim 1, wherein the elastic material layer comprises a material selected from the group consisting of a thermoplastic material, a thennoset material, and combinations thereof.
3. The flexible packaging material of Claim 1 or 2, wherein the elastic material layer comprises a polymer selected from the group consisting of a styrene polymer, an isoprene polymer, an ethylene polymer, a propylene polymer, a butadiene polymer, a butylene polymer, a diene polymer, a polyurethane polymer, an acetate polymer, copolymers thereof, and mixtures thereof.
4. The flexible packaging material of any one of Claims 1-3, wherein the elastic material layer comprises a thickness of about 50-100 pm.
5. The flexible packaging material of any one of Claims 1-4, wherein the metal foil layer comprises Al.
6. The flexible packaging material of any one of Claims 1-5, wherein the metal foil layer comprises a thickness of about 20-60 pm.
7. The flexible packaging material of any one of Claims 1-6, wherein the sealant material layer comprises a material selected from the group consisting of nylon (ONY), a polypropylene (PP) resin, an ethylene and acrylic acid (EAA) a copolymer resin, copolymers thereof, onentations thereof, and mixtures thereof.
8. The flexible packaging material of any one of Claims 1-7, wherein the sealant material layer comprises a thickness of about 30-100 pm.
9. The flexible packaging material of any one of Claims 1-8, further comprising at least one interlaminar adhesive layer.
10. The flexible packaging material of Claim 9, wherein a position of the at least one interlaminar adhesive layer is selected from the group consisting of disposed between the elastic material layer and the metal foil layer, disposed between the metal foil layer and the sealant material layer, and combinations thereof.
11. The flexible packaging material of Claim 9 or 10, wherein the at least one interlaminar adhesive layer comprises a material selected from the group consisting of a urethane adhesive, an acrylic adhesive, a polyolefin adhesive, and combinations thereof.
12. The flexible packaging material of any one of Claims 9-11, the at least one interlaminar adhesive layer comprises a thickness of about 5-15 pm.
13. A flexible energy storage device, comprising: the flexible packaging material of any one of Claims 1-12; a cathode; an anode; and a separator disposed between the another and the cathode.
14. The flexible energy storage device of Claim 13, further comprising an electrolyte.
15. The flexible energy storage device of Claim 13 or 14, wherein at least one of the cathode and the anode comprises an electron beam cured polymer binder.
16. A method of forming a flexible energy storage device, comprising: disposing an energy storage device assembly between a top packaging material and a bottom packaging material, wherein the top and bottom packaging materials each comprise the flexible packaging material of Claim 1; and sealing the top and bottom packaging materials to form a sealed packaging, wherein the energy storage device assembly and the sealed packaging form a flexible energy storage device.
17. The method of Claim 16, wherein sealing comprises a sealing temperature of about 130-210°C.
18. The method of Claim 16 or 17, wherein sealing comprises a sealing pressure of about 25-60 psi.
19. The method of any one of Claims 16-18, wherein sealing comprises a sealing time of about 2-10 second.
20. A method of forming a flexible packaging material, comprising: disposing a metal foil layer over an elastic material layer; and disposing a sealant material layer over the metal foil layer.
21. The method of Claim 20, further comprising disposing a first interlaminar adhesive layer over the elastic material layer, and disposing the metal foil layer over the first interlaminar adhesive layer.
22. The method of Claim 20 or 21, further comprising disposing a second interlaminar adhesive layer over the metal foil layer, and disposing the sealant material layer over the second interlaminar adhesive layer.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US202263371853P | 2022-08-18 | 2022-08-18 | |
US63/371,853 | 2022-08-18 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2024040134A1 true WO2024040134A1 (en) | 2024-02-22 |
Family
ID=87933783
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2023/072336 WO2024040134A1 (en) | 2022-08-18 | 2023-08-16 | Flexible packaging for use in energy storage devices, and method of manufacture thereof |
Country Status (1)
Country | Link |
---|---|
WO (1) | WO2024040134A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2779268A1 (en) * | 2011-11-07 | 2014-09-17 | Toppan Printing Co., Ltd. | Outer-covering material for electricity-storage device |
US20180076423A1 (en) * | 2015-03-27 | 2018-03-15 | Dai Nippon Printing Co., Ltd. | Packaging material for batteries, and battery |
JP2018147860A (en) * | 2017-03-09 | 2018-09-20 | 昭和電工パッケージング株式会社 | Exterior material for power storage device and power storage device |
-
2023
- 2023-08-16 WO PCT/US2023/072336 patent/WO2024040134A1/en unknown
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2779268A1 (en) * | 2011-11-07 | 2014-09-17 | Toppan Printing Co., Ltd. | Outer-covering material for electricity-storage device |
US20180076423A1 (en) * | 2015-03-27 | 2018-03-15 | Dai Nippon Printing Co., Ltd. | Packaging material for batteries, and battery |
JP2018147860A (en) * | 2017-03-09 | 2018-09-20 | 昭和電工パッケージング株式会社 | Exterior material for power storage device and power storage device |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11777070B2 (en) | Compositions and methods for dry electrode films having reduced binder content | |
US11349119B2 (en) | Method for making silicon-containing composite electrodes for lithium-based batteries | |
US20190237748A1 (en) | Compositions and methods for energy storage devices having improved performance | |
EP2503628B1 (en) | Current collector for bipolar secondary battery | |
US20170271678A1 (en) | Primer Surface Coating For High-Performance Silicon-Based Electrodes | |
US20210249657A1 (en) | Compositions and methods for silicon containing dry anode films | |
KR20180121411A (en) | Positive electrode, lithium secondarty battery comprising the positive electrode, and method for manufacturing the positive electrode | |
KR20210143777A (en) | Compositions and methods for dry electrode films comprising elastomeric binders | |
JP2022518395A (en) | Compositions and Methods for Prelithiumized Energy Storage Devices | |
JP4283598B2 (en) | Non-aqueous electrolyte solution and lithium ion secondary battery | |
JP2018174038A (en) | Binder for lithium ion secondary battery negative electrode, negative electrode for lithium ion secondary battery and lithium ion secondary battery using the same | |
CN110265629B (en) | Negative electrode and lithium ion secondary battery | |
KR20210007273A (en) | Composite anode active material, and Anode and Lithium secondary battery comprising the same | |
CN107644977A (en) | The preparation method of lithium ion cell electrode | |
KR20160036577A (en) | Lithium secondary battery and electrolyte solution for lithium secondary batteries | |
US20230361278A1 (en) | Positive electrode for secondary battery and secondary battery including the same | |
JP2023182616A (en) | Non-aqueous solvent electrolyte compositions for energy storage devices | |
JP2022547501A (en) | Method for manufacturing secondary battery | |
EP3605667A1 (en) | Lithium ion secondary battery, and manufacturing method and inspection method for negative electrode for lithium ion secondary battery | |
KR20200033737A (en) | Sulfur-carbon composite and lithium secondary battery including the same | |
WO2024040134A1 (en) | Flexible packaging for use in energy storage devices, and method of manufacture thereof | |
US20210104740A1 (en) | Methods of prelithiating silicon-containing electrodes | |
US20220416247A1 (en) | Multilayer and/or multidimensional electrode films for energy storage devices, and methods thereof | |
WO2023238325A1 (en) | Negative electrode active material layer, negative electrode, and lithium-ion rechargeable battery | |
US20230268478A1 (en) | Methods for fabicating high capacity electrodes |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 23765430 Country of ref document: EP Kind code of ref document: A1 |