Polymer battery module packaging sheet and a method of manufacturing the same
| Title: | Polymer battery module packaging sheet and a method of manufacturing the same |
|---|---|
| Patent Number: | 9,865,846 |
| Publication Date: | January 09, 2018 |
| Appl. No: | 13/275918 |
| Application Filed: | October 18, 2011 |
| Abstract: | A polymer battery module packaging sheet includes, as essential components, a base layer (61), an aluminum layer (62), chemical conversion coatings (64a, 64b) coating the opposite surfaces of the aluminum layer (62), and an innermost layer (63). The chemical conversion coatings (64a, 64b) are formed by processing the opposite surfaces of the aluminum layer (62) by a phosphate treatment method. The base layer (61) and the innermost layer (63) are bonded to the chemical conversion coatings (64a, 64b) of the aluminum layer (62) with adhesive layers (65a, 65b), respectively. |
| Inventors: | Yamashita, Takanori (Tokyo-To, JP); Okushita, Masataka (Tokyo-To, JP); Yamada, Kazuki (Tokyo-To, JP); Yamashita, Rikiya (Tokyo-To, JP); Miyama, Hiroshi (Tokyo-To, JP); Mochizuki, Youichi (Tokyo-To, JP) |
| Assignees: | DAI NIPPON PRINTING CO., LTD. (Tokyo, JP) |
| Claim: | 1. A polymer battery module packaging sheet for forming an embossed type packaging comprising: an oriented polyester film, an oriented nylon film, a first chemical conversion coating, an aluminum layer, a second chemical conversion coating, an adhesive layer, and a heat-sealable resin layer, the above layers being provided in this order, wherein the heat-sealable resin layer is formed of a cast polypropylene, and wherein the first chemical conversion coating is formed on the aluminum layer on the side of the oriented nylon film, and configured to prevent separation of the oriented nylon film and the aluminum layer during an embossing process and heat-sealing. |
| Claim: | 2. The polymer battery module packaging sheet according to claim 1 , wherein the cast polypropylene heat-sealable resin layer is formed of an ethylene-propylene copolymer resin. |
| Claim: | 3. The polymer battery module packaging sheet according to claim 2 , wherein the ethylene-propylene copolymer resin is ethylene-rich-random polypropylene resin. |
| Claim: | 4. The polymer battery module packaging sheet according to claim 1 , wherein the the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. |
| Claim: | 5. The polymer battery module packaging sheet according to claim 1 , wherein the cast polypropylene heat-sealable resin layer contains an ethylene-butene-propylene terpolymer, and the adhesive layer and the heat-sealable resin layer are formed by a coextrusion lamination method. |
| Claim: | 6. The polymer battery module packaging sheet according to claim 1 , wherein the cast polypropylene heat-sealable resin layer is formed of an ethylene-rich polypropylene resin. |
| Claim: | 7. The polymer battery module packaging sheet according to claim 1 , wherein the adhesive layer is formed of a material containing an acid-modified polypropylene resin as a principal component, the cast polypropylene heat-sealable resin layer includes a layer formed of an ethylene-rich random polypropylene resin having an ethylene content in the range of 5% to 10% by mol, and the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. |
| Claim: | 8. The polymer battery module packaging sheet according to claim 1 , wherein the aluminum layer covers an entire surface of the oriented polyester film and the oriented nylon film. |
| Claim: | 9. The polymer battery module packaging sheet according to claim 1 , wherein the aluminum layer has an iron content of 0.3 to 0.9 percent by weight. |
| Claim: | 10. The polymer battery module packaging sheet according to claim 9 , wherein the first chemical conversion coating and the second chemical conversion coating are formed from an aqueous solution comprising a mixture of a phenolic resin, a trivalent chromium fluoride compound, and phosphoric acid. |
| Claim: | 11. The polymer battery module packaging sheet according to claim 10 , wherein the cast polypropylene heat-sealable resin layer is formed of an ethylene-propylene copolymer resin. |
| Claim: | 12. The polymer battery module packaging sheet according to claim 10 , wherein the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. |
| Claim: | 13. The polymer battery module packaging sheet according to claim 10 , wherein the cast polypropylene heat-sealable resin layer contains an ethylene-butene-propylene terpolymer, and the adhesive layer and the heat-sealable resin layer are formed by a coextrusion lamination method. |
| Claim: | 14. A polymer battery module packaging sheet for forming an embossed type packaging comprising: an oriented polyester film, an oriented nylon film, a first chemical conversion coating, an aluminum layer, a second chemical conversion coating, an adhesive layer, and a heat-sealable resin layer, the above layers being provided in this order, wherein the heat-sealable resin layer is formed of a cast polypropylene, which contains 5% or above of a low crystalline ethylene-butene copolymer, a low-crystalline propylene-butene copolymer, an amorphous ethylene-propylene copolymer, or an amorphous propylene-ethylene copolymer, and wherein the first chemical conversion coating is formed on the aluminum layer on the side of the oriented nylon film, and configured to prevent separation of the oriented nylon film and the aluminum layer during an embossing process and heat-sealing. |
| Claim: | 15. The polymer battery module packaging sheet according to claim 14 , wherein the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. |
| Claim: | 16. The polymer battery module packaging sheet according to claim 14 , wherein the cast polypropylene heat-sealable resin layer contains an ethylene-butene-propylene terpolymer, and the adhesive layer and the heat-sealable resin layer are formed by a coextrusion lamination method. |
| Claim: | 17. The polymer battery module packaging sheet according to claim 14 , wherein the cast polypropylene heat-sealable resin layer is formed of an ethylene-rich polypropylene resin. |
| Claim: | 18. The polymer battery module packaging sheet according to claim 14 , wherein the adhesive layer is formed of a material containing an acid-modified polypropylene resin as a principal component, the cast polypropylene heat-sealable resin layer includes a layer formed of an ethylene-rich random polypropylene resin having an ethylene content in the range of 5% to 10% by mol, and the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. |
| Claim: | 19. The polymer battery module packaging sheet according to claim 14 , wherein the aluminum layer covers an entire surface of the oriented polyester film and the oriented nylon film. |
| Claim: | 20. The polymer battery module packaging sheet according to claim 14 , wherein the aluminum layer has an iron content of 0.3 to 0.9 percent by weight. |
| Claim: | 21. The polymer battery module packaging sheet according to claim 20 , wherein the first chemical conversion coating and the second chemical conversion coating are formed from an aqueous solution comprising a mixture of a phenolic resin, a trivalent chromium fluoride compound, and phosphoric acid. |
| Claim: | 22. The polymer battery module packaging sheet according to claim 21 , wherein the cast polypropylene heat-sealable resin layer is formed of an ethylene-propylene copolymer resin. |
| Claim: | 23. The polymer battery module packaging sheet according to claim 21 , wherein the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. |
| Claim: | 24. The polymer battery module packaging sheet according to claim 21 , wherein the cast polypropylene heat-sealable resin layer contains an ethylene-butene-propylene terpolymer, and the adhesive layer and the heat-sealable resin layer are formed by a coextrusion lamination method. |
| Claim: | 25. The polymer battery module packaging sheet according to claim 14 , wherein the cast polypropylene heat-sealable resin layer is formed of an ethylene-propylene copolymer resin. |
| Claim: | 26. The polymer battery module packaging sheet according to claim 25 , wherein the ethylene-propylene copolymer resin is ethylene-rich-random polypropylene resin. |
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| Other References: | Sep. 21, 2012 Office Action issued in U.S. Appl. No. 13/495,740. cited by applicant Mar. 15, 2013 Office Action issued in U.S. Appl. No. 13/495,740. cited by applicant Mar. 27, 2014 Office Action issued in U.S. Appl. No. 13/495,740. cited by applicant Oct. 7, 2013 Office Action issued in U.S. Appl. No. 13/495,740. cited by applicant Abstract of JP-A-1999-200985 published Feb. 16, 1999. cited by applicant Apr. 9, 2015 Office Action issued in U.S. Appl. No. 13/495,740. cited by applicant Oct. 15, 2015 Office Action issued in U.S. Appl. No. 13/495,740. cited by applicant Mar. 25, 2016 US Office Action issued in U.S. Appl. No. 13/495,740. cited by applicant |
| Primary Examiner: | Kruer, Kevin R |
| Attorney, Agent or Firm: | Oliff PLC |
| Accession Number: | edspgr.09865846 |
| Database: | USPTO Patent Grants |
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