JP6614038B2 - 電池用包装材料 - Google Patents
電池用包装材料 Download PDFInfo
- Publication number
- JP6614038B2 JP6614038B2 JP2016112470A JP2016112470A JP6614038B2 JP 6614038 B2 JP6614038 B2 JP 6614038B2 JP 2016112470 A JP2016112470 A JP 2016112470A JP 2016112470 A JP2016112470 A JP 2016112470A JP 6614038 B2 JP6614038 B2 JP 6614038B2
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- Prior art keywords
- layer
- metal layer
- packaging material
- battery packaging
- thickness
- Prior art date
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Description
項1. 少なくとも、基材層、金属層、及びシーラント層が順に積層されたシート状の積層体が成形された電池用包装材料であって、
前記電池用包装材料は、前記シーラント層側から前記基材層側に突出するようにして成形され、前記シーラント層側に電池素子が収容される略直方体状の空間を備えており、
前記電池用包装材料を前記基材層側から平面視した際、略矩形状に突出した部分の互いに対向する角部を結ぶ直線上の厚み方向の断面において、前記電池用包装材料の中心部から端部にかけて、順に、第1湾曲部と、第2湾曲部とを備えており、
前記第1湾曲部における前記金属層の厚みaと、前記第2湾曲部における前記金属層の厚みcと、前記第1湾曲部と前記第2湾曲部との中間に位置する部分における前記金属層の厚みbとが、以下の関係を充足する、電池用包装材料。
a≧b>cまたはa≧c>b
項2. 前記電池用包装材料を平面視した際、前記略矩形状に突出した部分の中心部における前記金属層の厚みが、30μm未満である、項1に記載の電池用包装材料。
項3. 前記第1湾曲部における前記金属層の厚みaが、30μm未満である、項1または2に記載の電池用包装材料。
項4. 前記第1湾曲部と前記第2湾曲部との中間に位置する部分における前記金属層の厚みbが、30μm未満である、項1〜3のいずれかに記載の電池用包装材料。
項5. 前記第2湾曲部における前記金属層の厚みcが、30μm未満である、項1〜4のいずれかに記載の電池用包装材料。
項6. 前記金属層が、アルミニウム箔により形成されている、項1〜5のいずれかに記載の電池用包装材料。
項7. 前記基材層と前記金属層との間に接着層が積層されてなる、項1〜6のいずれかに記載の電池用包装材料。
項8. 少なくとも正極、負極、及び電解質を備えた電池素子が、項1〜7のいずれかに記載の電池用包装材料内に収容されている、電池。
本発明の電池用包装材料10は、図3に示すように、少なくとも、基材層1、金属層3、及びシーラント層4が順次積層された積層体からなる。本発明の電池用包装材料10において、基材層1が最外層になり、シーラント層4は最内層になる。即ち、電池の組み立て時に、電池素子の周縁に位置するシーラント層4同士が熱溶着して電池素子を密封することにより、電池素子が封止される。
本発明の電池用包装材料10は、図1及び図2に示すように、シーラント層4側から基材層1側に突出するようにして成形されている。具体的には、本発明の電池用包装材料10は、上記の積層構造を有するシート状の積層体を成形することによって、シーラント層4側から基材層1側に突出するようにして成形されている。当該成形は、例えば、略矩形状の雄型と、この雄型とクリアランスを有する雌型からなるストレート金型を用いて、雄型側にシーラント層4が位置するように雌型上に上記の積層体を載置し、積層体を所定の圧力(面圧)で押さえることにより行うことができる。このような成形により、本発明の電池用包装材料10を基材層1側から平面視した際、電池用包装材料10には、略矩形状に突出した部分10aが形成されている。また、成形によって、本発明の電池用包装材料10には、シーラント層4側に電池素子が収容される略直方体状の空間10bが形成されている。
[基材層1]
本発明の電池用包装材料10において、基材層1は、最外層に位置する層である。基材層1を形成する素材については、絶縁性を備えるものであることを限度として特に制限されるものではない。基材層1を形成する素材としては、例えば、ポリエステル、ポリアミド、エポキシ樹脂、アクリル樹脂、フッ素樹脂、ポリウレタン、珪素樹脂、フェノール樹脂、ポリエーテルイミド、ポリイミド、及びこれらの混合物や共重合物等が挙げられる。
本発明の電池用包装材料10において、接着層2は、基材層1と金属層3を強固に接着させるために、これらの間に設けられる層である。
本発明の電池用包装材料10において、金属層3は、電池用包装材料10の強度向上の他、電池内部に水蒸気、酸素、光などが侵入することを防止するためのバリア層として機能する層である。上記のとおり、本発明においては、図5または図6に示されるように、第1湾曲部12における金属層3の厚みaと、第2湾曲部14における金属層3の厚みcと、第1湾曲部12と第2湾曲部14との中間に位置する部分13における金属層3の厚みbとが、a≧b>cまたはa≧c>bの関係を充足している。本発明の電池用包装材料10においては、このような構成を充足していることにより、例えば金属層3の厚みが30μm未満と非常に薄い場合にも、ピンホールやクラックが好適に抑制されている。
成形後の電池用包装材料10における金属層3の厚みa,b,cが上記本発明の関係になるAl−Fe系アルミニウム箔は、溶解、鋳造、スラブ、面削、ホモゲナイズ(均質化処理)、熱間圧延、冷間圧延、中間焼鈍、冷間圧延、箔圧延、最終焼鈍などの各工程を行うことにより製造することができる。溶解工程及び鋳造工程において、例えば、JIS規格A8079H−Oを溶解し、鋳塊を作製する。熱間圧延工程においては、均質化処理後の合金材料を高温下で圧延する。本工程における合金材料の熱間圧延温度は、280〜300℃とすることが好ましい。続いて、冷間圧延工程において、熱間圧延された合金材料を冷間圧延し、薄く延ばす。本工程における合金材料の冷間圧延温度は、110〜240℃とすることが好ましい。例えば、冷間圧延温度を調整することにより、電池用包装材料の成形後の上記厚みa,b,cを調整することができる。さらに、中間焼鈍工程においては、熱処理により冷間圧延後の合金材料内部のひずみを取り除き、組織を軟化させ、展延性を向上させる。本工程における処理温度は、380〜400℃であることが好ましく、特に390℃であることが好ましい。また、処理時間は1.5〜2.5時間とすることが好ましい。例えば、この処理時間を調整することにより、電池用包装材料の成形後の上記厚みa,b,cを調整することができる。
本発明の電池用包装材料10において、シーラント層4は、最内層に該当し、電池の組み立て時にシーラント層同士が熱溶着して電池素子を密封する層である。
本発明の電池用包装材料10において、接着層は、金属層3とシーラント層4を強固に接着させために、これらの間に必要に応じて設けられる層である。
本発明の電池用包装材料10の製造方法については、所定の組成の各層を積層させた積層体を得た後、金属層3の上記の厚みa、b、cが、a≧b>cまたはa≧c>bの関係を充足する限り、特に制限されないが、例えば、以下の方法が例示される。
本発明の電池用包装材料10は、正極、負極、電解質等の電池素子を密封して収容するための包装材料として使用される。
基材層1/接着層2/金属層3が順に積層された積層体に対して、サーマルラミネート法でシーラント層4を積層させることにより、基材層1/接着層2/金属層3/シーラント層4が順に積層された積層体からなる電池用包装材料10を製造した。電池用包装材料の具体的な製造条件は、以下に示す通りである。
アルミニウム箔Aは、それぞれ、東洋アルミニウム株式会社製のアルミニウム箔A8021を圧延して得られたものである。熱間圧延工程において290℃圧延し、続いて、冷間圧延工程において、冷間圧延温度200℃とし、さらに中間焼鈍工程を390℃にて処理時間2.5時間実施した。アルミニウム箔Aにおいては、冷間圧延温度を200℃にし、徐冷効果により合金材料の均一化を保持しつつ、中間焼鈍工程の処理時間を2.5時間としたことにより、合金材料内部のひずみが緩和され、成形時の展延性に影響を及ぼしたと考えられる。
アルミニウム箔Bは、それぞれ、東洋アルミニウム株式会社製のアルミニウム箔A8021を圧延して得られたものである。熱間圧延工程において290℃圧延し、続いて、冷間圧延工程において、冷間圧延温度200℃とし、さらに、中間焼鈍工程を390℃にて処理時間1.5時間実施した。アルミニウム箔Bにおいては、中間焼鈍工程の処理時間を1.5時間としたことにより、合金材料内部のひずみに変化が生じ、成形時の展延性に影響を及ぼしたと考えられる。
アルミニウム箔Cは、それぞれ、東洋アルミニウム株式会社製のアルミニウム箔A8021を圧延して得られたものである。熱間圧延工程において290℃圧延し、続いて、冷間圧延工程において、冷間圧延温度100℃とし、さらに中間焼鈍工程を390℃にて処理時間1.5時間実施した。アルミニウム箔Cでは、冷間圧延温度が100℃であることにより、合金材料の均一性に変化が生じ、成形時の展延性に影響を及ぼしたと考えられる。
実施例1−18及び比較例1−9で得られた電池用包装材料10を裁断して、120×80mmの短冊片を作製し、これを試験サンプルとした。30×50mmの矩形状の雄型とこの雄型とのクリアランスが0.5mmの雌型からなるストレート金型を用い、雄型側にシーラント層側が位置するように雌型上に上記試験サンプルを載置し、試験サンプルを0.1MPaの押え圧(面圧)で押えて、冷間成形(引き込み1段成形)した。成形深さは、0.5mm単位で変えて、各成形深さにおいて、それぞれ10枚の試験サンプルについて、金属層のピンホール及びクラックの発生の有無を確認した。10枚全ての試験サンプルにシワや、ピンホール及びクラックがない場合の成形深さを限界成形深さとし、下記の基準で成形性を評価した。結果を表1に示す。
○:限界成形深さ6.0mm以上
△:限界成形深さ4.0mm〜5.5mm
×:限界成形深さ3.5mm以下
上記の成形性の評価と同様にして、実施例1−18及び比較例1−9の電池用包装材料10から作製したサンプルを限界成形深さ3.0mmに成形した。次に、成形後の電池用包装材料10について、基材層側から平面視した際、略矩形状に突出している部分10aの互いに対向する角部pを結ぶ直線上において、ミクロトーム(大和光機工業製:REM−710リトラトーム)にて厚み方向に裁断して電池用包装材料10を2分割し、得られた断面をレーザー顕微鏡(キーエンス製:VKX−100)で観察して、第1湾曲部における金属層の厚みaと、第2湾曲部における金属層の厚みcと、第1湾曲部と前記第2湾曲部との中間に位置する部分における金属層の厚みbとを計測して、a、b、cの関係を求めた。結果を表1に示す。
比較例1において、アルミニウム箔Cとして、厚み35μmの代わりに厚み40μmものを使用したこと以外は、比較例1と同様にして参考例の電池用包装材料Aを製造し、成形性の評価、限界成形深さ3.0mmで成形した後の金属層の厚み(μm)の測定を以下の通り行った。
基材層1を構成するナイロン(厚み25μm、)、金属層2を構成する後述のアルミニウム箔C(厚み40μm)を用いた。アルミニウム箔Cは、フェノール樹脂、フッ化クロム化合物(三価)、及びリン酸からなる処理液をロールコート法によりアルミニウム箔Cの両面にそれぞれ10mg/m2塗布(乾燥重量)し、皮膜温度が180℃以上となる条件で20秒間焼付けすることにより化成処理した。
アルミニウム箔C(厚み40μm)は、東洋アルミニウム株式会社製のアルミニウム箔A8021を以下の条件で圧延して得られたものである。熱間圧延工程において290℃で圧延し、続いて、冷間圧延工程の冷間圧延温度100℃とし、さらに中間焼鈍工程を390℃にて処理時間1.5時間実施した。
上記で得られた電池用包装材料Aを裁断して、120×80mmの短冊片を作製し、これを試験サンプルとした。30×50mmの矩形状の雄型とこの雄型とのクリアランスが0.5mmの雌型からなるストレート金型を用い、雄型側にシーラント層側が位置するように雌型上に上記試験サンプルを載置し、試験サンプルを0.1MPaの押え圧(面圧)で押えて、冷間成形(引き込み1段成形)した。成形深さは、0.5mm単位で変えて、各成形深さにおいて、それぞれ10枚の試験サンプルについて、金属層のピンホール及びクラックの発生の有無を確認した。10枚全ての試験サンプルにシワや、ピンホール及びクラックがない場合の成形深さを限界成形深さとし、下記の基準で成形性を評価した。結果を表2に示す。
○:限界成形深さ6.0mm以上
△:限界成形深さ4.0mm〜5.5mm
×:限界成形深さ3.5mm以下
上記の成形性の評価と同様にして、電池用包装材料Aから作製したサンプルを限界成形深さ3.0mmに成形した。次に、成形後の電池用包装材料Aについて、基材層側から平面視した際、略矩形状に突出している部分の互いに対向する角部を結ぶ直線上において、ミクロトーム(大和光機工業製:REM−710リトラトーム)にて厚み方向に裁断して電池用包装材料Aを2分割し、得られた断面をレーザー顕微鏡(キーエンス製:VKX−100)で観察して、第1湾曲部における金属層の厚みaと、第2湾曲部における金属層の厚みcと、第1湾曲部と前記第2湾曲部との中間に位置する部分における金属層の厚みbとを計測して、a、b、cの関係を求めた。結果を表2に示す。
2 接着層
3 金属層
4 シーラント層
5 接着層
10 電池用包装材料
10a 略矩形状に突出した部分
10b 略直方体状の空間
11 電池用包装材料を平面視した際の中心部
12 第1の湾曲部
13 第1の湾曲部と第2の湾曲部との中間に位置する部分
14 第2の湾曲部
15 端部
Claims (9)
- 少なくとも、基材層、金属層、及びシーラント層が順に積層されたシート状の積層体が成形された電池用包装材料であって、
前記電池用包装材料は、前記シーラント層側から前記基材層側に突出するようにして成形され、前記シーラント層側に電池素子が収容される略直方体状の空間を備えており、
前記電池用包装材料を前記基材層側から平面視した際、略矩形状に突出した部分の互いに対向する角部を結ぶ直線上の厚み方向の断面において、前記電池用包装材料の中心部から端部にかけて、順に、第1湾曲部と、第2湾曲部とを備えており、
前記第1湾曲部における前記金属層の厚みaが、30μm未満であり、
前記第1湾曲部における前記金属層の厚みaと、前記第2湾曲部における前記金属層の厚みcと、前記第1湾曲部と前記第2湾曲部との中間に位置する部分における前記金属層の厚みbとが、以下の関係を充足する、電池用包装材料。
a≧b>cまたはa≧c>b - 少なくとも、基材層、金属層、及びシーラント層が順に積層されたシート状の積層体が成形された電池用包装材料であって、
前記電池用包装材料は、前記シーラント層側から前記基材層側に突出するようにして成形され、前記シーラント層側に電池素子が収容される略直方体状の空間を備えており、
前記電池用包装材料を前記基材層側から平面視した際、略矩形状に突出した部分の互いに対向する角部を結ぶ直線上の厚み方向の断面において、前記電池用包装材料の中心部から端部にかけて、順に、第1湾曲部と、第2湾曲部とを備えており、
前記第1湾曲部と前記第2湾曲部との中間に位置する部分における前記金属層の厚みbが、30μm未満であり、
前記第1湾曲部における前記金属層の厚みaと、前記第2湾曲部における前記金属層の厚みcと、前記第1湾曲部と前記第2湾曲部との中間に位置する部分における前記金属層の厚みbとが、以下の関係を充足する、電池用包装材料。
a≧b>cまたはa≧c>b - 少なくとも、基材層、金属層、及びシーラント層が順に積層されたシート状の積層体が成形された電池用包装材料であって、
前記電池用包装材料は、前記シーラント層側から前記基材層側に突出するようにして成形され、前記シーラント層側に電池素子が収容される略直方体状の空間を備えており、
前記電池用包装材料を前記基材層側から平面視した際、略矩形状に突出した部分の互いに対向する角部を結ぶ直線上の厚み方向の断面において、前記電池用包装材料の中心部から端部にかけて、順に、第1湾曲部と、第2湾曲部とを備えており、
前記第2湾曲部における前記金属層の厚みcが、30μm未満であり、
前記第1湾曲部における前記金属層の厚みaと、前記第2湾曲部における前記金属層の厚みcと、前記第1湾曲部と前記第2湾曲部との中間に位置する部分における前記金属層の厚みbとが、以下の関係を充足する、電池用包装材料。
a≧b>cまたはa≧c>b - 前記第1湾曲部における前記金属層の厚みaが、30μm未満である、請求項2又は3に記載の電池用包装材料。
- 前記第1湾曲部と前記第2湾曲部との中間に位置する部分における前記金属層の厚みbが、30μm未満である、請求項1又は3に記載の電池用包装材料。
- 前記第2湾曲部における前記金属層の厚みcが、30μm未満である、請求項1又は2に記載の電池用包装材料。
- 前記金属層が、アルミニウム箔により形成されている、請求項1〜6のいずれかに記載の電池用包装材料。
- 前記基材層と前記金属層との間に接着層が積層されてなる、請求項1〜7のいずれかに記載の電池用包装材料。
- 少なくとも正極、負極、及び電解質を備えた電池素子が、請求項1〜8のいずれかに記載の電池用包装材料内に収容されている、電池。
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