TWI425697B - Current collecting post seal for high durability lithium-ion cells - Google Patents

Description

Collector column seal for high durability lithium ion batteries

SUMMARY OF THE INVENTION The object of the present invention is to produce a high durability lithium ion battery through innovations in the structure and processing method for fabricating a lithium ion battery cover. The novel structure and method disclosed for making the outer cover extends the useful life of the synthetic battery. The present invention provides a battery for long-term applications such as household energy storage applications or hybrid electric vehicle applications.

Hermetic seals often determine a critical issue in the life of a lithium ion battery because a high voltage of the cell provides water or oxygen reduction if water vapor or oxygen molecules are present in the electrolyte. These problems often cause improper battery seals. Traditionally, lithium ion batteries are small in size and capacity. As an example, a cylindrical type 18650 battery is used, which has a size of 18 metric in diameter and 65 mm in height. This battery capacity is in the range of about 2.8 Ah to 1.4 Ah depending on the type of cathode material being used. In view of the space utilized by the construction of the outer cover, the metal-to-polymer interface at the current collecting column of the battery is usually small (only supported by a shape such as an insulating layer of an O-ring), and the interface is thus unable to provide a The long diffusion path is directed to oxygen, water molecules or other gases or liquids that penetrate the metal to the polymer interface. Because of the accelerated decompression of the metal to polymer interface, the foregoing conditions become more severe once high temperature cycling conditions (e.g., conditions such as continued high power operation) are applied to the cells. The same problem occurs with other types of lithium ion batteries such as prismatic batteries or even lithium polymer type batteries.

A cover assembly for a lithium ion battery container has an outer cover for sealing a top opening of a battery container, the outer cover defining one or more openings for the current collecting column. The outer cover assembly further includes: a current collecting column extending through each of the openings and having a gap between the current collecting column and the outer cover; a top flange surrounding each set a flow column, disposed at a top surface opposite and offset from the outer cover, and an edge extending radially outward from the current collecting post beyond the opening; a bottom flange surrounding each of the current collecting columns, arranged to Relatively and offset from a bottom surface of the outer cover, and an edge extending radially outward from the current collecting post beyond the opening; and a first polymeric body for each current collecting column. The first polymer main system is continuous and extended to fill all gaps formed between the outer cover, the current collecting columns, the top flange and the bottom flange, and the first polymer The main system is welded to the exposed cover, the header, the top flange and the bottom flange.

Purpose of the invention

In order to improve the above problems, a novel structure of a battery container cover disclosed has a novel method for manufacturing a cover. Durable lithium ion batteries have an extended service life (target of 20 years) which is expected by the appropriate structure and method implemented in the battery container cover. For large batteries (over 10 Ah capacity) used in large energy storage systems and/or high power applications such as electric or hybrid electric vehicles (which require long life and continuous high power capability), especially Good sealing at these collectors is important.

The key concepts applied to the outer cover structure are as follows:

a. Increase the diffusion path of gases and/or liquids into or out of the battery.

b. Strengthen a metal to polymer interface at the collector of the cell.

Example I : The basic form of the invention

Figure 1 (a) is a top plan view showing an outer cover 1 open to the top of one of the battery containers. To clearly illustrate the method of the present invention, the stepwise assembly of the outer cover is shown in the form of a side view of Figures 1(b) through 1(f).

Figure 1 (b) shows the first step for making the outer cover assembly. A first polymer body 2 is disposed on a top surface and a bottom surface of the container cover 1 through an injection molding process. The collecting column 3 extending through the opening 4 in the outer cover 1 is stabilized by the injection molding process to fill the gap between the outer cover and the collecting columns.

Figure 1 (c) shows one of the top flange 5 and one bottom flange 6 disposed on the conductive column. The flanges are forced toward each other and the injection molding polymer master system is sandwiched between the two. The top flange and the bottom flange are welded to the injection molded polymer. This step is extremely important and is preferably performed at a temperature close to the softening point of the polymer. The advantages of the flanges being forced toward each other (preferably using a punch, using a screw mechanism to bolt the top flange and the bottom flange together on a bolt or the like) are summarized as follows: 1. The injection molded polymer and the contact and fusion between the top flange and the bottom flange are ensured.

2. Ensure contact and fusion between the injection molded polymer and the collectors. This is very important because battery cells that are often subjected to high power operation may cause decompression bonding between the polymer and the current collecting column.

Figure 1 (d) shows a separate insulating layer 7 disposed at least on the bottom surface of each of the bottom flanges for isolating the bottom flange and the electrodes of the battery unit while also blocking gas or liquid therein. Possible leakage 8 occurring at the interface between the current collecting column and the injection molded polymer.

Figure 1 (e) shows the welded 9 (for example: laser welding method) to the top flange of the collecting column to avoid gas or liquid molecules from the interface between the top flange and the collecting column Any possibility of penetration.

Finally, as shown in Figure 1(f), the area at the top flange is filled with the second polymer body 10 to ensure that between the edge of the top flange and the first molded polymer body. No leakage will occur at the interface.

The key factors and methods involved in making the outer cover shown in the examples of the present invention are summarized as follows:

a. Injection molding for making a cover monomer containing the headers.

b. Compress the outer cover unit by forcing the top and bottom flanges toward each other.

c. Apply the release material to the bottom surface of each bottom flange.

d. Laser welding between the top flanges and the collectors.

e. filling a first polymer into the first injection molded first polymer body to block possible penetration between the edge of the top flange and the first polymer body.

The key factors and methods involved in making the aforementioned covers are indispensable for solving the following list of issues:

1. The injection molding process is possible and preferred in the present invention because a cover monomer can be fabricated by simply processing a good interface integrity between the first polymer body and the container cover. Since the injection molding process is a high pressure process, the polymer disposed on the top of the outer cover of the container can exhibit a characteristic "texture" having a preferred polymer crystal orientation, wherein the system can distinguish the polymer from being deposited thereon. Other ways on the top of the container cover. The injection molding process utilized and one of the "outer cap/polymer monomer" structures ensure the interface integrity. The foregoing makes the invention novel and indispensable.

2. Strengthen the interface between the current collecting column and the injection molded first polymer body. This is achieved by forcing the two together when the top flange and the bottom flange are welded to the polymeric material. The present invention also tends to increase the diffusion path by fusing to the top and bottom flanges of the injection molded first polymeric body. Without the use of the top flange and the bottom flange, the leakage can occur more easily at the interface between the current collecting column and an injection molded first polymer body due to a shorter diffusion path.

3. Other steps involved in blocking any new interface established when using the top flange and the bottom flange are indispensable. The step includes: coating the insulating material on the bottom surface of the bottom flange (the penetration through the interface of the collecting columns from the possible two-way leakage into or out of the battery is delayed, as shown in FIG. 1 (d) as indicated); laser welding between the top flange and the collectors (to avoid leakage through the interface of the top flange and the header, as indicated in Figure 1(e) And more than one layer of polymer coating to protect the edge of the top flange (to avoid leakage through the interface at the edge of the top flange, as indicated in Figure 1(f)).

The material selection for the injection molded polymer layer includes, but is not limited to, polyethylene (PE), polypropylene (PP), polyurethane (PU), nylon, polyethylene terephthalate (PET), acrylonitrile. Butadiene styrene copolymer (ABS), fluorinated ethylene propylene copolymer (FEP), polyimide, polyacrylic, epoxy resin (Epoxy Resin) or a combination of the foregoing listed materials . The region of the injection molded first polymeric body between the top flange and the bottom flange preferably extends beyond the edge of the opening for hosting the header. Preferably, the distance between the injection molded first polymer body to the edge of the opening of the current collector column is more than 0.5 cm. That is, the polymer system should extend beyond the edge of the opening by at least 0.5 centimeters. As long as the weight of the polymer is acceptable for the overall battery design, one of the entire outer cover is fully covered. The overall thickness of the injection molded first polymer body is preferably more than 0.2 mm. If the weight of a polymer layer is acceptable for the overall cell design, a thicker polymer layer with better integration is promoted.

The material selection utilized for the top flange comprises a metal or a polymeric flange. If metal is used, a seal (eg, a laser seal) between the top flange and the header should be made. If a polymeric top flange is used instead of a metal top flange, a high temperature weld between the top flange and the header should be performed. The top flange is preferably sized larger than the opening for hosting the header. It is better to extend more than 0.5 cm or more beyond the edge of the opening.

The material selection utilized for the bottom flange should be a metal with high electrical conductivity because the bottom flange is used to connect to multiple electrodes or small side portions of the electrode. The bottom flange is preferably sized larger than the opening for hosting the header. It is better to extend more than 0.5 cm or more beyond the edge of the opening.

The material used to coat the surface of the bottom flange can be selected to be the same as or different from the material used for the injection molded polymer layer. The selections include polyethylene, polypropylene, polyurethane, nylon, polyethylene terephthalate, acrylonitrile butadiene styrene copolymer, fluorinated ethylene propylene copolymer, polyimine, polyacrylonitrile, Epoxy resin or a combination of the foregoing listed materials. A portion of the bottom flange that is connected to the electrodes should not be coated.

The material selection for coating the top of the injection molded first polymer body can be the same as or different from the injection molded first polymer body. Again, the choices include polyethylene, polypropylene, polyurethane, nylon, polyethylene terephthalate, acrylonitrile butadiene styrene copolymer, fluorinated ethylene propylene copolymer, polyimine, polypropylene Cyanide, epoxy resin or a combination of the foregoing listed materials.

In the example of the present invention, if the injection molding polymer does not exhibit sufficient fusion on the top flange and the bottom flange and the current collecting columns and on the surface of the outer cover, the bottom layer 11 should be used. To fuse the top flange/the injection molded first polymer body, the bottom flange/the injection molded first polymer body, the current collecting column/the injection molded first polymer body, and the The interface between the outer cover surface/the injection-molded first polymer body (as indicated by Figure 1(g)). The material used for the underlayer is styrene butadiene rubber (SBR), an adhesive, or any other material that has excellent adhesion to the metal surface and the injection molded polymer. In addition, the underlayer can be an anodic polarization layer on the surface of the metal to be fused, which increases the roughness of the metal surface to enhance adhesion of the metal to the polymer layer. An anode-polarized metal surface and a combination of a polymer primer layer are also encompassed by the present invention.

Example II : an assembly of an alternative form of the invention

Referring to Figures 2(a) through 2(c), a header, a top flange, a bottom flange and an outer cover are assembled first by mechanical assembly or welding. In the configuration shown in Figure 2(a), the plurality of current collecting columns, the top flange, and the bottom flange are assembled using a mold and an outer cover, and the polymer injection molding system is carried out throughout the assembly. on. The resulting outer cover becomes a single body as shown in Fig. 2(b). The top flanges are then sealed to the headers, and then a second polymer body is placed on top of the injection molded first polymer body as shown in Figure 2(c). Since the high pressure is used during the injection molding process, the condition that the top flange and the bottom flange are urged toward each other in the first manufacturing method described above can be achieved by the injection molding process of the present invention. It should be noted that a seal system, such as by laser welding, between the top flange and the current collecting column can be performed prior to the injection molding process. The header, top flange, can be fabricated by assembling two components, wherein one of the previously combined components is a header/top flange assembly or a header/bottom flange assembly, The assembly of the bottom flange is further feasible, wherein the two components are each made by machining a metal block, casting or extruding the metal.

The container cover can be designed in any shape (eg, circular, elliptical, rectangular, etc.), while the edges are shaped to be flat except for the shape (see Figures 2(e) through 3(e) figure). In Figures 2(e) through 3(e), the edges of all of the container covers are designed to have a "lip" type of structure for further increase in diffusion length and polymer/cover interface integration.

After the outer lid is welded to the battery container of the finished battery, an electrolyte can be filled through the injection crucible 12. A final seal can be accomplished by welding a metal ball 13 or a small cover 14 to the top of the injection bowl 12, as shown in Figure 2(d).

Similar to the underlying material to be used in Example I , in the present example, if the injection molded polymer does not exhibit sufficient interfacial properties (attachment or fusion) to the top flange and the bottom flange and on the surface of the outer cover An underlying material system can be applied first to the surface of the flange surface. At the interface between the top flange/the injection molded polymer, the bottom flange/the injection molded polymer, the current collecting column/the injection molded polymer, and the outer cover surface/the injection molded polymer (as indicated in Fig. 1(g)) welding occurs during the subsequent injection molding process. The material used for the underlayer is styrene butadiene rubber (SBR), an adhesive, or any other material that has excellent adhesion to the metal surface and the injection molded polymer. In addition, the underlayer can be an anodic polarization layer on the surface of the metal to be fused, which increases the roughness of the metal surface to enhance adhesion of the metal to the polymer layer. An anode-polarized metal surface and a combination of a polymer primer layer are also encompassed by the present invention.

Example III: an extension of the invention

A battery cover may contain not only the openings of the positive and negative current collecting columns, but also additional openings for electrolyte filling or safe access. More than one embodiment is provided herein for the design and method of making a battery cover, including a plurality of current collecting columns, an electrolyte filling opening, and a safety vent.

For the sake of clarity, the method described in Example II is utilized in the examples of the present invention. An outer cover shown in Fig. 3(a) contains a notch 15 around the opening for electrolyte filling. The gap having a reduced metal thickness is designed as a safety port that breaks outward when the internal battery pressure is abnormally increased. A current collecting column, a top flange and a bottom flange are assembled first by mechanical assembly or welding. In the configuration shown in Fig. 3(a), a plurality of current collecting columns, a top flange, and a bottom flange are assembled with respect to the outer cover using a mold, and then the injection molding system is carried out over the entire assembly. . The resulting outer cover is changed to a single body 18 as shown in Fig. 3(b). During the injection molding process, by adjusting the shape of the mold, the ejected polymer can be selected to completely cover the indentations, partially cover (at a shallower depth), or not cover the indentations. In Figure 3(b), the exiting polymer system partially covers the gaps. Partial coverage is preferred because the gaps are protected by the polymer layer, but the polymer layer does not significantly impede its normal implementation. The top flange is then sealed to the current collecting column, and then a second polymeric body is provided on top of the injection molded first polymeric body as shown in Figure 3(c). It should be noted that the second polymer host system can completely cover the notched regions, partially cover (at a shallower depth), or not cover the gaps. In Fig. 3(c), the second polymer body 10 is shown not to cover the gap (safety port) region. In the present example, the outer cover structure is not necessarily limited to the configuration and design of the safety port or the electrolyte injection port shown in the drawings. Additional examples are given herein for the configuration and design of the safety port and the electrolyte injection port. For example, as shown in FIG. 3(d), a safety port can be designed to be combined with the injection port; or as shown in FIG. 3(e), the safety port can be installed as one of the battery covers. Separate an independent design mechanism at location 17.

In all of the examples given above, increasing the distance to one of the diffusion paths and any openings present on the outer cover of the cell to enhance the metal-on-polymer interface forms the basis of the present invention. The position and shape design of the current collecting column, electrolyte injection port, and safety port are not limited to the given examples in the inventive examples. The structure of the polymer layer and the method for constructing a battery cover are any combination and number of collector bars, electrolyte injection ports, and safety ports that are to be present on top of the battery cover. The present invention is also applied in a configuration in which the container and the outer cover replace the current collecting column and only one current collecting column is required.

1‧‧‧ container cover

2‧‧‧First polymer body

3‧‧‧ Collector

4‧‧‧ Opening of the collecting column

5‧‧‧Top flange

6‧‧‧Bottom flange

7‧‧‧Separate insulation

8‧‧‧ Possible route of leakage

9‧‧‧welding

10‧‧‧Second polymer body

11‧‧‧ bottom layer

12‧‧‧Injection

13‧‧‧metal ball

14‧‧‧Small cover

15‧‧‧ gap

16‧‧‧ gap in molding polymer coverage

17‧‧‧Safety port

18‧‧‧Single

Figure 1 (a) is a top view of a container outer cover of the present invention;

1(b) to 1(g) are side views of an outer cover assembly of the present invention, showing a sequential asymptotic step of a first manufacturing method;

2(a) to 2(c) are side views of an outer cover assembly of the present invention, showing a step-by-step step of a second manufacturing method;

Figure 2 (d) is a side view of the outer cover assembly of the present invention, showing various seals of the electrolyte injection opening;

3(a) to 3(d) are side views of the outer cover assembly in the present invention, showing various safety ports and electrolyte injection holes and a sealing method thereof; and FIG. 3(e) is the same in the present invention. A side view of the lid assembly showing another variation of the position of a safety port and an electrolyte injection hole.

1‧‧‧ container cover

4‧‧‧ Opening of the collecting column

12‧‧‧Injection

Claims (31)

An outer lid assembly for a lithium ion battery container, the outer lid assembly comprising: an outer cover for sealing a top opening of a battery container, the outer cover defining one or more openings; and a plurality of openings Units, each unit comprising: one of the one or more openings; a current collecting column extending through the one opening and having a gap between the outer cover and a cover; a top flange, Revolving around the current collecting column, a top surface that is disposed opposite and offset from the outer cover, and an edge that extends radially outward from the current collecting post beyond the one opening; a bottom flange that surrounds the a current collecting column, a bottom surface disposed opposite and offset from the outer cover, and an edge extending radially outward from the current collecting post beyond the one opening; and a first polymer body for the a current collecting column, wherein the first polymer main system is continuous and extended to fill all gaps formed between the outer cover, the current collecting column, the top flange and the bottom flange, and the first polymerization The owner system is fused to the cover that is in contact The current collecting column of the top flange and the bottom flange. The cover assembly of claim 1, wherein each unit further comprises an insulating material on a bottom surface of the bottom flange for electrically insulating the bottom flange from other components of the battery . The cover assembly of claim 1, wherein each unit further comprises a weld seal between the header and the top flange. The cover assembly of claim 1, wherein each unit further comprises a second polymer body, the second polymer main system covering and being welded to a top surface of the first polymer body and the top A surface of the flange, wherein the interface between the first polymer body and the top flange is included. The cover assembly of claim 1, wherein a surface of at least one of the outer cover, the current collecting column, the top flange and the bottom flange is provided with a bottom layer for urging the surfaces to be welded To the first polymer body. The cover assembly of claim 5, wherein the bottom layer is composed of at least one of styrene butadiene rubber (SBR), an adhesive, and an anodic polarization layer of the material provided with the underlayer. The cover assembly of claim 1, wherein the first polymer main system is formed from polyethylene (PE), polypropylene (PP), polyurethane (PU), nylon, polyethylene terephthalate. (PET), acrylonitrile butadiene styrene copolymer (ABS), fluorinated ethylene propylene copolymer (FEP), polyimide, polyacrylic, epoxy resin (Epoxy Resin), Or a combination of the foregoing materials. The cover assembly of claim 1, wherein the top flange is made of metal or a polymer, and the bottom flange is made of a metal having high conductivity. The outer cover assembly of claim 1, wherein the top flange and the bottom flange extend radially outward beyond the edge of the one opening by at least 0.5 centimeters. The cover assembly of claim 4, wherein the second polymer main system is formed from polyethylene, polypropylene, polyurethane, nylon, polyethylene terephthalate, acrylonitrile butadiene styrene copolymer , a fluorinated ethylene propylene copolymer, polyimine, polyacrylonitrile, epoxy, or a combination of the foregoing. The cover assembly of claim 1, wherein the cover further comprises at least one of an electrolyte filling opening and a safety port mechanism, and the first polymer main system is welded to the electrolyte filling At least one of an opening and the safety port mechanism. An outer lid assembly for a lithium ion battery container, the outer lid assembly comprising: an outer cover for sealing a top opening of a battery container, the outer cover defining one or more openings; and a plurality of openings Units, each unit comprising: one of the one or more openings; a current collecting column extending through the one opening and having a gap between the outer cover and the outer cover; a top flange Revolving around the current collecting column, a top surface that is disposed opposite and offset from the outer cover, and an edge that extends radially outward from the current collecting column beyond the one opening; a bottom flange that surrounds The current collecting column is arranged to be relatively And offset from a bottom surface of the outer cover, and an edge extending radially outward from the current collecting column beyond the one opening; a first polymer body for the current collecting column, wherein the first polymerization The owner system is continuous and extended to fill all gaps formed between the outer cover, the current collecting column, the top flange and the bottom flange, and the first polymer main system is welded to the contact The outer cover, the current collecting post, the top flange and the bottom flange; an insulating material attached to a bottom surface of the bottom flange for electrically insulating the bottom flange from the battery a member; and a second polymer body for the current collecting column, covering and being fused to a top surface of the first polymer body and a surface of the top flange, wherein the first polymer is included A mating interface between the body and the top flange. A method of making an outer cover assembly for a lithium ion battery container, the method comprising: providing an outer cover for sealing a top opening of a battery container, the outer cover defining one or more openings And providing a plurality of units, for each unit: providing one of the one or more openings; providing a current collecting column extending through the one opening and having a gap between the outer cover and the outer cover; Providing a first polymer body by injection molding a polymer to fill a gap between the current collecting column and the outer cover, and in the outer cover ring Providing a polymer coating around the portion of the header to both the bottom surface and the bottom surface of the outer cover, the first polymer host system being fused to the outer cover and the current collecting column; a top flange surrounding the header and extending radially outward from the header beyond an edge of the one opening, the top flange being disposed on the top surface of the outer cover and the first The polymeric body is in contact; providing a bottom flange surrounding the current collecting column and extending radially outward from the current collecting post beyond an edge of the one opening, the bottom flange being disposed over the outer cover The bottom surface is in contact with the first polymer body; and pressure is applied to the top and bottom flanges of the current collecting column to weld the flange to the first polymer body. The method of claim 13, wherein the flange and the first polymer host system are previously heated prior to applying pressure to weld the flange to the first polymer body. The method of claim 13, wherein, for each unit, further comprising coating a bottom surface of the bottom flange by an insulating material for electrically insulating the bottom flange from other members of the battery. The method of claim 13, wherein, for each unit, further comprising providing a second polymer body, the second polymer host system covering and being fused to a top surface of the first polymer body and the top A surface of the flange, wherein the interface between the first polymer body and the top flange is included. The method of claim 13, wherein, for each unit, further comprising providing a bottom layer to a surface of the member fused to the first polymer body for causing the surfaces to be welded to the first polymer body . The method of claim 17, wherein the underlayer is composed of at least one of styrene butadiene rubber, an adhesive, and an anodic polarization layer of the material provided with the underlayer. The method of claim 13, wherein the first polymer main system is formed from polyethylene, polypropylene, polyurethane, nylon, polyethylene terephthalate, acrylonitrile butadiene styrene copolymer, A fluorinated ethylene propylene copolymer, polyimine, polyacrylonitrile, epoxy, or a combination of the foregoing. The method of claim 13, wherein the top flange is made of a metal or a polymer, and the bottom flange is made of a metal having high conductivity. The method of claim 13, wherein the top flange and the bottom flange extend radially outward beyond the edge of the one opening by at least 0.5 cm. The method of claim 16, wherein the second polymer main system is formed from polyethylene, polypropylene, polyurethane, nylon, polyethylene terephthalate, acrylonitrile butadiene styrene copolymer, A fluorinated ethylene propylene copolymer, polyimine, polyacrylonitrile, epoxy or a combination of the foregoing. An outer cover assembly for manufacturing a lithium ion battery container The method comprises: providing an outer cover for sealing a top opening of a battery container, the outer cover defining one or more openings; and providing a plurality of units for each unit: providing the one Or one of the openings; providing a current collecting column extending through the one opening and having a gap between the outer cover; providing a top flange surrounding the current collecting column, An edge disposed opposite and offset from a top surface of the outer cover and extending radially outward from the current collecting post beyond the one opening; providing a bottom flange surrounding the current collecting column, arranged to Opposite and offset from a bottom surface of the outer cover and extending radially outward from the current collecting post beyond the edge of the one opening; and providing a first polymer body by injection molding for use in the set a flow column, wherein the first polymer main system is continuous and extended to fill all gaps formed between the outer cover, the current collecting column, the top flange and the bottom flange, and the first polymer The main system is welded to the contact The outer cover, the collecting column, the top flange and the bottom flange. The method of claim 23, for each unit, further comprising coating a bottom surface of the bottom flange by an insulating material for electrically insulating the bottom flange from other members of the battery. The method of claim 23, for each unit, further comprising providing a second polymer body, the second polymer body Covering and being fused to a top surface of the first polymeric body and a surface of the top flange, wherein the bonding interface between the first polymeric body and the top flange is included. The method of claim 23, for each unit, further comprising providing a bottom layer to a surface of the member fused to the first polymer body for causing the surfaces to be welded to the first polymer body . The method of claim 26, wherein the underlayer is composed of at least one of styrene butadiene rubber, an adhesive, and an anodic polarization layer of the material provided with the underlayer. The method of claim 23, wherein the first polymer main system is formed from polyethylene, polypropylene, polyurethane, nylon, polyethylene terephthalate, acrylonitrile butadiene styrene copolymer, A fluorinated ethylene propylene copolymer, polyimine, polyacrylonitrile, epoxy, or a combination of the foregoing. The method of claim 23, wherein the top flange is made of a metal or a polymer, and the bottom flange is made of a metal having high conductivity. The method of claim 23, wherein the top flange and the bottom flange extend radially outward beyond the edge of the one opening by at least 0.5 cm. The method of claim 25, wherein the second polymer main system is formed from polyethylene, polypropylene, polyurethane, nylon, polyethylene terephthalate, acrylonitrile butadiene styrene copolymer, Fluorinated ethylene A propylene copolymer, polyimine, polyacrylonitrile, epoxy or a combination of the foregoing.