JP6667509B2 - フレキシブルバッテリー、その製造方法、フレキシブルバッテリーを含む補助バッテリー、及び、モバイル電子機器 - Google Patents
フレキシブルバッテリー、その製造方法、フレキシブルバッテリーを含む補助バッテリー、及び、モバイル電子機器 Download PDFInfo
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- JP6667509B2 JP6667509B2 JP2017512960A JP2017512960A JP6667509B2 JP 6667509 B2 JP6667509 B2 JP 6667509B2 JP 2017512960 A JP2017512960 A JP 2017512960A JP 2017512960 A JP2017512960 A JP 2017512960A JP 6667509 B2 JP6667509 B2 JP 6667509B2
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Description
フレキシブルバッテリーは、フレキシブルな性質を有するニッケル−カドミウムバッテリー、ニッケル−メタルハイドライドバッテリー、ニッケル−水素バッテリー、リチウムイオンバッテリー等が挙げられる。特に、リチウムイオンバッテリーは、鉛蓄電池と、ニッケル−カドミウムバッテリー、ニッケル−水素バッテリー、ニッケル−亜鉛バッテリー等、他のバッテリーと比べて、単位重量当たりのエネルギー密度が高く、急速充電が可能であるため、高い活用度を有する。
本発明の好ましい実施例によれば、前記パターンは、前記外装材の少なくとも一面に形成される第1パターンと、前記電極組立体に前記第1パターンと同一の方向に形成される第2パターンと、を含み、前記第1パターン及び第2パターンは、互いに一致するように配置され得る。
また、前記バッテリーの断面厚さは、0.2〜5mmであり得る。
また、前記第1樹脂層は、PPa(acid modified polypropylene)、CPP(casting polyprolypene)、LLDPE(Linear Low Density Polyethylene)、LDPE(Low Density Polyethylene)、HDPE(High Density Polyethylene)、ポリエチレンテレフタレート、ポリプロピレン、エチレンビニルアセテート(EVA)、エポキシ樹脂、及び、フェノール樹脂の中から選択された1種の単一層で形成されるか、又は、2種以上が積層されて構成され得る。
また、本発明は、電極組立体と、前記電極組立体を電解液とともに封止する外装材と、を含み、前記電極組立体及び外装材は、曲げの時に長さ方向に対する収縮及び弛緩のためのパターンが同一の方向性を有するようにそれぞれ形成され、前記パターンが形成された領域は、下記の数式2によるθが5.0゜〜47゜を満足する領域を含むフレキシブルバッテリーを提供する。
なお、本発明は、前述したフレキシブルバッテリーと、前記外装材の表面を覆う軟質のハウジングと、を含み、前記ハウジングは、充電対象機器との電気的な連結のための少なくとも一つの端子部が設けられる補助バッテリーで具現され得る。
すなわち、温度25℃、湿度65%の環境でフレキシブルバッテリーの両端部に力を加えて、曲げられた部分においての曲率が25mmになるように曲げ、100回の充放電を行うと、図11aに示されたように、本発明によるフレキシブルバッテリー100、100’の場合、曲げなかったときの容量(135mAh)に比べて略15%減少した容量(116mAh)を示し、100回が行われても性能が維持されたが(実施例)、外装材側にのみ収縮及び弛緩のためのパターンを形成したフレキシブルバッテリーの場合、最初に比べて略60%減少した容量(52mAh)で徐々に減少する性能を示し、50回を超える場合、充放電が不可能であり(比較例1)、外装材及び電極組立体の両方にパターンが形成されない単純板状の形態に設けられるフレキシブルバッテリーである場合、最初に比べて略80%減少した容量(26mAh)の低下が発生し、30回を超える場合、充放電が不可能であることを確認できた(比較例2)。
一例として、図3に示されたように、本発明によるフレキシブルバッテリー100’は、前記第1パターン124が、前記電極組立体110及び電解液を収容するための収容部を形成する第1領域S1にのみ形成されてもよい。
なお、前記陽極112と陰極116との間に配置される分離膜114は、不織布層114aの一面又は両面に、ナノ繊維ウェブ層114bを含み得る。
一例として、前記膨潤性ポリマーは、ポリビニリデンフルオライド(PVDF)、ポリ(ビニリデンフルオライド−コ−ヘキサフルオロプロピルレン)、パーフルオロポリマー、ポリビニルクロライド又はポリビニリデンクロライド及びこれらの共重合体及びポリエチレングリコールジアルキルエーテル及びポリエチレングリコールジアルキルエステルを含むポリエチレングリコール誘導体、ポリ(オキシメテレン−オリゴ−オキシエチレン)、ポリエチレンオキシド及びポリプロピレンオキシドを含むポリオキシド、ポリビニルアセテート、ポリ(ビニルピロリドン−ビニルアセテート)、ポリスチレン及びポリスチレンアクリロニトリル共重合体、ポリアクリロニトリルメチルメタクリレート共重合体を含むポリアクリロニトリル共重合体、ポリメチルメタクリレート、ポリメチルメタクリレート共重合体、及び、これらの中の1種以上の混合された混合物が使用され得る。
また、前記分離膜の平均厚さは、10〜100μmであり得、好ましくは10〜50μmであり得る。これは、分離膜の平均厚さが10μm未満であれば、分離膜があまりに薄いため、バッテリーの反復的な曲がり及び/又は広がりによる分離膜の長期的な耐久性を確保できないことがあり、100μmを超過すると、フレキシブルバッテリーの薄肉化に不利なので、前記範囲内の平均厚さを有することが良い。
前記外装材120は、一定の面積を有する板状の部材よりなり、内部に前記電極組立体110及び電解液を収容することによって、外力から前記電極組立体110を保護するためのものである。
これは、前記第1樹脂層121a、122aの平均厚さが20μm未満であれば、第1外装材121及び第2外装材122の周縁をシールする過程で、互いに重なって折れる第1樹脂層121a、122a間の接合力が低下するか、電解液の漏洩を防止するための気密性を確保するのに不利なことがあり、平均厚さが80μmを超過すると、非経済的であり、薄形化に不利であるからである。
これは、金属層の平均厚さが5μm未満であれば、収容部の内部に湿気が浸透するか、又は、収容部内部の電解液が外部に漏水され得るからである。
前記接着層は、金属層121b、122bと第1樹脂層121a、122aとの間の接着力を高める役目とともに、外装材の内部に収容される電解液が外装材の金属層121b、122bに到逹することを防止し、酸性の電解液により金属層121b、122bが腐食され、及び/または、第1樹脂層121a、122aと金属層121b、122bとが剥離されることを予防できる。また、フレキシブルバッテリー100、100’の使用過程中に異常過熱等のような問題が発生し、フレキシブルバッテリーが膨脹する場合にも、電解液が漏出されることを防止し、安全性に対する信頼性を付与できる。
これは、前記ドライラミネート層の平均厚さが1μm未満であれば、接着力があまりに弱くて、金属層121b、122bと第2樹脂層121c、122cとの間の剥離が発生し得、7μmを超過すると、不要にドライラミネート層の厚さが厚くなって、収縮及び弛緩のためのパターンを形成するのに不利な影響を及ぼし得るからである。
一例として、前記電解液は、非水性有機溶媒とリチウム塩との溶質が含まれた有機電解液を使用できる。ここで、前記非水性有機溶媒としては、カーボネート、エステル、エーテル、又は、ケトンを使用できる。前記カーボネートとしては、ジメチルカーボネート(DMC)、ジエチルカーボネート(DEC)、ジプロピルカーボネート(DPC)、メチルプロピルカーボネート(MPC)、エチルプロピルカーボネート(EPC)、メチルエチルカーボネート(MEC)、エチレンカーボネート(EC)、プロピレンカーボネート(PC)、ブチレンカーボネート(BC)等が使用され得、前記エステルとしては、ブチロラクトン(BL)、デカノライド(decanolide)、バレロラクトン(valerolactone)、メバロノラクトン(mevalonolactone)、カプロラクトン(caprolactone)、n−メチルアセテート、n−エチルアセテート、n−プロピルアセテート等が使用され得、前記エーテルとしては、ジブチルエーテル等が使用され得、前記ケトンとしては、ポリメチルビニルケトンがあるが、本発明は、非水性有機溶媒の種類に限定されるものではない。
まず、厚さが30μmのアルミニウム材質の金属層を用意し、前記金属層の一面にCPP(casting polypropylene)で構成された厚さが40μmの第1樹脂層を形成し、前記金属層の他面に厚さが10μmのナイロンフィルムで構成された第2樹脂層を形成し、この際、前記第1樹脂層と前記金属層との間に、アクリル酸の含量として共重合体内に6重量%で含有する酸変性ポリプロピレン層を、5μmで介在させて、全体厚さ85μmの外装材を製造した。
実施例1と同様に実施して製造するが、バッテリーに設けられたパターンの増加した表面積比率等を下記表3又は表4のように変更させて、フレキシブルバッテリーを製造した。
実施例1と同様に実施して製造するが、用意した外装材のみを図13のような製造装置に投入し、パターンを形成した(1100)。その後、パターンが形成されていない電極組立体1000を、パターンが形成された外装材でシールし、図14のような断面構造を有する下記表5のようなフレキシブルバッテリーを製造した。
実施例1と同様に実施して製造するが、バッテリーの外装材及び電極組立体の両方にパターンを形成せず、図1のような形状の下記表4のようなフレキシブルバッテリーを製造した。
実施例1と同様に実施して製造するが、バッテリーに具備されたパターンの増加した表面積比率を下記表5のように変更させて、フレキシブルバッテリーを製造した。
製造されたフレキシブルバッテリーに対して下記の物性を評価した後、表3〜表5に示す。
下記のような数式1及び数式2の満足可否を確認し、満足する場合、○、不満足する場合、×で表示した。
温度25、湿度65%の環境で完全放電されたフレキシブルバッテリーの両端部側に力を加えて、曲げられた部分においての曲率が25mmになるように曲げた状態で、完全充電し、充電容量を測定した後、さらに完全放電させ、再充電する過程を、合計100回実施し、平均充電容量を測定した。但し、100回実施前に充電容量が0mAhになる場合、最初0mAhで測定されたときまでに測定された充電容量の平均を計算した。
フレキシブルバッテリーの曲げ及び元の状態への復元を1セットにして、500セット進行後、バッテリーの外観を光学顕微鏡で観察し、電解液の漏液発生、外装材のクラック発生等、外観異常が発生したか否かを評価し、評価結果は、異常がない場合を0、異常程度がひどいほど、1〜5で評価した。
温度25℃、湿度65%の環境で完全充電されたフレキシブルバッテリーにおいて、バッテリーの長さ方向に対して1/2地点を折って、油圧ラム(Hydraulic Ram)で0.8kN/24cm2(=26mm×91.5mm)荷重を加えて、完全フォールディングさせた後、さらに広げ、その後、120秒間電圧を測定し、測定後、120秒になったときの電圧を表に示す。
フレキシブルバッテリーの曲げ及びその復元過程を繰り返す途中に、きしむ騒音が発生したか否かに対して評価し、騒音が発生しない場合を0、騒音の発生程度がひどいほど、及び/又は、発生回数が多いほど、1〜5で示す。
Claims (12)
- 電極組立体と、
前記電極組立体を電解液とともに封止する外装材と、
曲げの時の長さ方向に対する収縮及び弛緩のために前記外装材に形成された第1パターンと、前記電極組立体に形成された第2パターンとを含むパターンと、を含み、
前記第1パターンと前記第2パターンとは、それぞれ、長さ方向に沿って形成された山部と谷部とを含み、前記第1パターンの山部と谷部とのそれぞれは、前記第2パターンの山部と谷部とのそれぞれに一致するように形成され、前記外装材は、前記電極組立体の上部面を覆う第1外装材と、前記電極組立体の下部面を覆う第2外装材とを含み、前記第1外装材に形成される前記第1パターンの山部と谷部とのそれぞれは、前記第2外装材に形成される前記第1パターンの山部と谷部とのそれぞれに一致するように形成され、
前記パターンが形成された領域は、下記の数式1による増加した表面積比率(Sdr)が、0.5〜40.0を満足する一領域を含むフレキシブルバッテリー:
[数式1]
- 前記第1パターン及び前記第2パターンは、長さ方向に沿って複数の山部及び谷部が交互に形成され、
前記山部及び谷部は、弧形断面、多角断面、又は、これらが相互組合された断面のうちのいずれかを有するように設けられることを特徴とする請求項1に記載のフレキシブルバッテリー。 - それぞれの山部及び谷部は、前記電極組立体及び外装材の幅方向と平行な方向に、連続的又は非連続的に形成されることを特徴とする請求項2に記載のフレキシブルバッテリー。
- 前記パターンは、前記電極組立体及び外装材に全体的に形成されるか、又は部分的に形成されることを特徴とする請求項2に記載のフレキシブルバッテリー。
- 隣合う山部の間隔又は谷部の間隔は、等間隔又は不等間隔を有するように形成されるか、又は、等間隔と不等間隔とが相互組合された形態に設けられることを特徴とする請求項2に記載のフレキシブルバッテリー。
- 前記パターンは、長さ方向に沿って連続的に形成されるか、又は非連続的に形成されることを特徴とする請求項1に記載のフレキシブルバッテリー。
- 前記外装材は、前記電極組立体及び電解液を収容する収容部を形成するための第1領域と、前記第1領域を取り囲むように配置され、シール部を形成するための第2領域と、を含み、
前記パターンのうち外装材に形成されるパターンは、前記第1領域にのみ形成されることを特徴とする請求項1に記載のフレキシブルバッテリー。 - 前記バッテリーの断面厚さは、0.2〜5mmであることを特徴とする請求項1に記載のフレキシブルバッテリー。
- 前記数式1による増加した表面積比率(Sdr)は、3.0〜23.0であることを特徴とする請求項1に記載のフレキシブルバッテリー。
- 請求項1〜9のいずれかに記載のフレキシブルバッテリーと、
前記外装材の表面を覆うハウジングと、を含み、
前記ハウジングは、充電対象機器との電気的な連結のための少なくとも一つの端子部が設けられる補助バッテリー。 - 電極組立体が電解液とともに外装材により封止されるフレキシブルバッテリーの製造方法において、
前記電極組立体及び前記外装材を同時に加圧して、曲げの時の長さ方向に対する収縮及び弛緩のためのパターンを、前記電極組立体及び前記外装材のそれぞれに形成し、
前記パターンは長さ方向に沿って形成された山部と谷部とを含み、前記外装材に形成される第1パターンの山部と谷部とのそれぞれは、前記電極組立体に形成される第2パターンの山部と谷部とのそれぞれに一致し、
前記外装材は、前記電極組立体の上部面を覆う第1外装材と、前記電極組立体の下部面を覆う第2外装材と、を含み、前記第1外装材に形成される前記第1パターンの山部と谷部とのそれぞれは、第2外装材に形成される山部と谷部とのそれぞれに一致すように形成され、
前記パターンが形成された領域は、下記数式1による増加した表面積比率(Sdr)が0.5〜40.0を満足する一領域を含むように、電極組立体及び外装材を同時に加圧して形成されるフレキシブルバッテリーの製造方法:
[数式1]
- 請求項10に記載の補助バッテリーを含むモバイル電子機器。
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