Patent Application
20170033329
The present invention relates to a composite film and a method of fabricating the same, and more particularly, to a highly flexible composite film with reduced interlayer deformation or interlayer exfoliation and a method of fabrication the same.
Generally, a pouch or a packing material for accommodating a liquid therein is demanded to prevent the liquid therein from being leaked to outside and to prevent outside moisture or foreign substances from being introduced into the same. A polymer resin is commonly used for such a pouch or a packing material. Such a polymer resin may be drawn or folded by a press to have a certain shape, e.g., a rectangular shape or a circular shape, and may be applied to various product packing materials.
Although a polymer resin for a pouch or a packing material in the related art becomes a thick film or a highly density layer to prevent a liquid from being leaked to outside and to prevent outside moisture or foreign substances from being introduced into the same, such an approach restricts improvement of flexibility or pliability of the packing material. Furthermore, in case of forming a composite structure by stacking other layers, various deformations or exfoliations may occur due to different thermal expansion coefficients.
The present invention provides a composite film that is sufficient flexible or pliability, prevents a liquid therein from being leaked to outside by reducing interlayer deformation or interlayer exfoliation, and prevents outside moisture or foreign substances from being introduced into the same.
The present invention also provides a method of economically and easily fabricating the above-stated composite film.
According to an aspect of the present invention, there is provided a composite film including a first protection layer; and a fabric layer adhered onto the first protection layer via an adhesive layer. According to an embodiment, the first protection layer is a polypropylene-based polymer resin, a polyethylene-based polymer resin, a copolymer thereof, or a mixture thereof. The polyethylene-based polymer resin is a polyethylene copolymer containing ethylene vinyl acetate copolymer (EVA), acrylic acid-ethylene copolymer (EAA), metacrylic acid-ethylene copolymer (EMAA), acrylic acid ethyl-ethylene copolymer (EEA), acrylic acid methyl-ethylene copolymer (EMA), or metacrylic acid-ethylene copolymer (EMMA).
According to an embodiment, the first protection layer has a thickness from about 10 μm to about 40 μm. The fabric layer comprises a cotton fabric, a hempen fabric, a woolen fabric, a silk fabric, a blended fabric, a union fabric, a non-woven fabric, or a microfiber fabric. Furthermore, the fabric layer includes Gore-Tex. According to an embodiment, the fabric layer has a thickness from about 100 μm to about 2,000 μm.
The composite film further includes a metal layer between the first protection layer and the fabric layer, wherein the metal layer comprises aluminum (Al), copper (Cu), iron (Fe), carbon (C), chromium (Cr), manganese (Mn), nickel (Ni), or an alloy thereof. The metal layer includes a metal foil or a metal thin-film. The metal layer has a thickness from about 1 μm to about 100 μm. Preferably, the metal layer has a thickness from about 1 μm to about 10 μm.
Furthermore, the composite film further comprises a second protection layer between the metal layer and the fabric layer. The second protection layer comprises nylon, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polybutylene naphthalate, or a derivative thereof. The second protection layer has a thickness from about 10 μm to about 30 μm. The adhesive includes an acryl-based adhesive or an epoxy-based adhesive.
According to another aspect of the present invention, there is provided a method of fabricating a composite film, the method including providing a first protection layer; forming a metal layer on a surface of the first protection layer; and forming a fabric layer on the other surface of the metal layer not contacting the first protection layer. According to another embodiment, the method further comprises, before the forming of the fabric layer, forming a second protection layer on the other surface of the metal layer, wherein the fabric layer is formed on the other surface of the second protection layer not contacting the metal layer.
The forming of the fabric layer includes applying an adhesive on the other surface of the second protection layer, stacking the fabric layer thereon, and drying the fabric layer. The forming of the fabric layer includes pressing the fabric layer by using a press. The fabric layer is formed on the first protection layer or the first protection layer is formed on the fabric layer.
According to an embodiment of the present invention, by laminating a fabric layer onto a surface of a protection layer (basic material layer) constituting a composite file, there are provided a composite film having excellent flexibility or pliability, and capable of improving life expectancy and product reliability of a packing material by reducing interlayer deformation or interlayer exfoliation due to a difference between thermal expansion coefficients of the basic material layer and the fabric layer and a method of fabricating the composite film.
Furthermore, according to an embodiment of the present invention, there may be provided a composite film, since it is difficult for a liquid, such as an electrolyte, and outside moisture to be introduced into a protection layer (basic material layer), a fabric layer is exposed as an outer casing in case of using the composite film as an outer casing for a lithium ion battery including an electrolyte or a pouch for accommodating an energy storage device, such as a capacitor or a double-layered capacitor, and a method of fabricating the composite film.
Furthermore, according to an embodiment of the present invention, there may be provided a highly flexible composite film, which employs a highly water-resistant basic material layer and a fabric layer so as to be used as outer casings for wearable smart devices including a watch, a belt, an eyeglass, and a battery, a battery including the outer casing, and a method of fabricating the same.
Hereinafter, exemplary embodiments will be described in detail with reference to accompanying drawings.
The invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the invention to those skilled in the art.
Furthermore, in the drawings, the thicknesses of layers and regions are exaggerated for clarity, and like reference numerals in the drawings denote like elements. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Although numerical terms (e.g., “first” and “second”) are used herein to describe various members, parts, regions, layers and/or sections, these members, parts, regions, layers and/or sections are not to be limited by these terms. These terms are only used to distinguish one member, part, region, layer or section from another member, part, region, layer or section. Thus, for example, a first member, part, region, layer or section discussed below could be termed a second, part, region, layer or section without departing from the teachings of the illustrated embodiments.
Referring to
The thermal fusing layer may comprise a polypropylene-based polymer resin, a polyethylene-based polymer resin, or a copolymer thereof (e.g., an ethylene-propylene copolymer) and may preferably comprise a polyethylene-based polymer resin or a copolymer thereof. Since the polyethylene-based polymer resin features lower melting point than the polypropylene-based polymer resin, a thermal fusion operation may be performed thereto at a relatively low temperature, e.g., a temperature from about 80° C. to about 130° C.
According to an embodiment of the present invention, the polyethylene-based polymer resin may comprise polyethylene (PE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), mid-density polyethylene (MDPE), or high-density polyethylene (HDPE). According to another embodiment of the present invention, the polyethylene-based polymer resin may be a polyethylene copolymer containing ethylene vinyl acetate copolymer (EVA), acrylic acid-ethylene copolymer (EAA), metacrylic acid-ethylene copolymer (EMAA), acrylic acid ethyl-ethylene copolymer (EEA), acrylic acid methyl-ethylene copolymer (EMA), or metacrylic acid-ethylene copolymer (EMMA). Thermal conductivity of a polyethylene-based polymer resin with a low melting point is reduced due to the fabric sheet layer 12 and, even if thickness of a composite film increases, thermal fusion may be performed or a packing material may be sealed at a relatively low temperature, and thus reliability and speed of a packing operation using the composite film 10 may be improved. According to an embodiment of the present invention, the composite film 10 may be used as an outer casing of a battery that may be fabricated at a low temperature.
The above-stated materials related to the first protection sheet layer 11 are merely examples, and the present invention is not limited thereto. For example, the first protection sheet layer 11 may comprise materials that may be thermally fused while being stable against moisture or an electrolyte, that is, a polyester-based resin, such as PET resin or nylon resin, or a polyamide-based resin.
The first protection sheet layer 11 may have a thickness from about 10 μm to about 40 μm. If thickness of the first protection sheet layer 11 is less than 10 μm, chemical resistance and leakage related to content, such as a salt or an electrolyte, occur and an outside moisture blocking characteristic is deteriorated. Furthermore, during a packing operation or a packaging operation using the composite film 10, adhesion thickness based on thermal fusion between bottom surfaces of the first protection sheet layer 11 is reduced, and thus sufficient mechanical strength and sealing characteristic cannot be maintained. If thickness of the first protection sheet layer 11 exceeds 40 μm, it is difficult to draw or fold the composite film 10 during a packing operation or a packaging operation and, due to the increased thickness of the composite film 10, flexibility thereof is deteriorated.
The fabric sheet layer 12 protects internal layers including the first protection sheet layer 11 from the outside environment, prevents the internal layers from being cracked based on flexibility of fibrous structure of the fabric sheet layer 12, and prevents an outer circumferential surface 12S of the composite film 10 (e.g., the outer circumferential surface is an outer skin of a pouch) from being cracked, thereby improving life expectancy of a product and securing durability and reliability of the composite film 10 during a drawing operation or a folding operation for a packing operation or a packaging operation. Furthermore, the fabric sheet layer 12 improves flexibility of the composite film 10 based on unique characteristics of a fiber structure thereof and absorbs and compensates deformation or interlayer exfoliation due to stresses based on a difference between thermal expansion coefficients of the internal layers and the fabric sheet layer 12 or, if the internal layers includes a plurality of stacked layers, stresses based on different thermal expansion coefficients of the internal layers, thereby maintaining structure of the composite film 10 stable.
Furthermore, when the fabric sheet layer 12 is used as a packing material, an interface exhibiting flexibility and a user-friendly texture or a user-friendly tactile impression may be embodied, thereby improving marketability and expanding possible applications thereof. For example, if the composite film 10 is applied as an outer casing of a wearable device, such as a smart cloth or a smart shoe, or is used as a pouch for a battery that is an energy supply of the wearable device, the composite film 10 may be attached to or integrated with existing clothes, existing shoes, existing bags, or existing camping equipments as an outer casing without a separate outer casing. Therefore, enabling development of products based on applications thereof and products with new dimensions and designs.
According to an embodiment of the present invention, the fabric sheet layer 12 may comprise a cotton fabric, a hempen fabric, a woolen fabric, a silk fabric, a blended fabric, a union fabric, a non-woven fabric, or a microfiber fabric. According to another embodiment of the present invention, the fabric sheet layer 12 may be a composite fiber layer. For example, the fabric sheet layer 12 may include a Gore-Tex formed by stacking a waterproof layer on a fabric layer. However, the above-stated materials are merely examples, and the present invention is not limited thereto. For example, the fabric sheet layer 12 may include any material layer that may be formed by being placed on the first protection sheet layer 11 with the adhesive layer 13 and being dried at a temperature including the room temperature (e.g., 25° C.), the temperature from about 20° C. to about 50° C. or being pressed by a press. The above-stated operations for stacking the fabric sheet layer 12 are merely examples, and the present invention is not limited thereto.
The fabric sheet layer 12 may be formed to have a thickness from about 100 μm to about 2,000 μm. If thickness of the fabric sheet layer 12 is less than about 100 μm, the fabric sheet layer 12 may be easily damaged by external shocks or may not be able to sufficiently suppress interlayer deformation or interlayer exfoliation based on differences between thermal expansion coefficients, and thus the fabric sheet layer 12 is not suitable as an outer casing. Furthermore, if thickness of the fabric sheet layer 12 exceeds 2,000 μm, it is difficult to draw or fold the composite film 10 in a packing operation using the composite film 10, e.g., an operation for fabricating a pouch, and thus increased processing cost and defects may be caused. Since thickness of the composite film 10 is increased, flexibility thereof may be deteriorated.
The adhesive 13 may be an acryl-based adhesive or an epoxy-based adhesive. However, the present invention is not limited thereto. The adhesive 13 may not only adheres the fabric sheet layer 12 to the first protection sheet layer 11, but also has certain elasticity to prevent the first protection sheet layer 11 and the fabric sheet layer 12 from being detached from each other when the composite film 10 is drawn or folded.
Referring to
The metal sheet layer 21 prevents the first protection sheet layer 11 from being swelled or deteriorated by moisture or a gas introduced into the first protection sheet layer 11 from outside environment. Furthermore, in a packing operation or a packaging operation, if content is a liquid material, e.g., an electrolyte, the metal sheet layer 21 prevents the content from being leaked via the first protection sheet layer 11 and maintains strength of an overall package.
The metal sheet layer 21 may comprise aluminum (Al), copper (Cu), iron (Fe), carbon (C), chromium (Cr), manganese (Mn), nickel (Ni), or an alloy thereof. For example, the metal sheet layer 21 may include iron for improving mechanical strength and may include an iron as a main ingredient for improving flexibility. If the metal sheet layer 21 includes an iron-containing material, an alloy including from 84% to 88.2% iron, less than or equal to 0.5% carbon, from 11% to 15% chromium, and from 0.3% to 0.5% manganese or an alloy including from 63.7% to 75.9% iron, from 0.1% to 0.3% carbon, from 12% to 18% chromium, and from 7% to 12% nickel may be used.
Thickness of the metal sheet layer 21 may be from about 0.1 μm to about 100 μm and may preferably be from about 1 μm to about 20 μm. If thickness of the metal sheet layer 21 is smaller than 0.1 μm, the metal sheet layer 21 may be easily cracked, broken, or damaged in a drawing operation or a folding operation for a packing operation or a packaging operation. If thickness of the metal sheet layer 21 exceeds 100 μm, it is difficult to draw or fold the metal sheet layer 21. Therefore, it is difficult to perform a packing operation or a packaging operation, and flexibility of a packed product and life expectancy thereof may be deteriorated.
The metal sheet layer 21 may be a metal foil or a metal thin-film. In case of the metal foil, an intermediate product for fabricating the composite film 20 may be formed by coating or laminating the first protection sheet layer 11 on a surface of the metal sheet layer 21. In case of the metal thin-film, the metal sheet layer 21 may be formed on the first protection sheet layer 11 via a vapor deposition operation, such as sputtering or thermal deposition, an electrolyteless plating operation, or a combination thereof.
If the metal sheet layer 21 is the thin-film, the metal sheet layer 21 may increase flexibility or pliability of the composite film 20. Thickness of the metal sheet layer 21 is within a range from about 0.1 μm to about 10 μm. The composite film 10, which is a thin-film of the metal sheet layer 21, is useful when the composite film 10 as described above is used as an outer battery casing for a battery including a solid electrolyte. Unlike a battery employing a liquid electrolyte, an electrolyte is unlikely be leaked out of an outer battery casing in a battery employing a solid electrolyte, and thus the metal sheet layer 21 may be formed as a thin-film or omitted.
The fabric sheet layer 12 is adhered onto the metal sheet layer 21 via the adhesive 13. The fabric sheet layer 12 increases flexibility and pliability of the composite film 20, thereby increasing flexibility and pliability of a packing material or a package employing the composite film 20 as an outer casing. For example, if the composite film 20 is used as an outer casing for a water bottle or a battery cell charged with an electrolyte, the composite film 20 may reduce swelling of the first protection sheet layer 11 due to the electrolyte and exfoliation and deformation due to a difference between thermal expansion coefficients of the first protection sheet layer 11 and the metal sheet layer 21, thereby improving life expectancy of a product.
Referring to
The second protection layer 31 may be formed by being coated or laminated onto a surface of the metal layer 21 to a certain thickness. The second protection layer 31 protects internal layers from outside and prevents the outer circumferential surface of a pouch formed of the composite film 10 from being cracked, and thus the overall fabricating process becomes easy.
The second protection layer 31 may include nylon, polyethylene, polyethylene terephthalate, polybutylene terephthalate, polybutylene naphthalate, or a derivative thereof. However, the present invention is not limited thereto. The second protection layer 31 may be formed by coating the liquefied polymer resin onto a surface of the metal layer 21 or forming films of the polymer resin in advance and stacking the films by using any of various laminating methods. Furthermore, a surface of the second protection layer 31 may be protected or formability of the second protection layer 31 may be improved by forming the second protection layer 31 to include a plurality of layers or forming a fluorine-based resin layer or an acryl-based resin layer on a surface of the second protection layer 31.
The second protection layer 31 may be formed to have a thickness from about 10 μm to about 30 μm. If thickness of the second protection layer 31 is smaller than 10 μm, it is difficult to perform a drawing operation or a folding operation for a packing operation or a packaging operation. If thickness of the second protection layer 31 exceeds 30 μm, a packing material employing the composite film 10 becomes too thick.
Hereinafter, a method of fabricating a composite film according to an embodiment of the present invention will be described. Since materials and thicknesses are identical to those described above, detailed descriptions thereof will be omitted.
Referring to
Referring to
According to some embodiments, in case of the laminating method, the first protection layer 11 and the fabric layer 12 may be rapidly and firmly adhered to each other by using a pressing method using a press. The composite film 10 without the metal layer 21 is useful when the composite film 10 as described above is used as an outer battery casing for a battery including a solid electrolyte, for example. Unlike a battery employing a liquid electrolyte, an electrolyte is unlikely be leaked out of an outer battery casing in a battery employing a solid electrolyte, and thus the composite film 10 without the metal layer 21 may be fabricated as an outer battery casing as described above.
Referring to
The metal layer 21 may be formed as a metal thin-film of a desired thickness by performing a sputtering operation or a plating operation to a surface of the first protection layer 11. The first protection layer 11 is provided first, and then the fabric layer 12 may be adhered to a surface of the metal layer 21, which is the surface without the first protection layer 11, via the adhesive 13. The fabric layer 12 may be located on a surface of the metal layer 21 via the adhesive 13 and may be formed by being dried at the room temperature or being pressed by a press at a certain pressure.
Referring to
In the operation S32 for forming the first protection layer 11 and the second protection layer 31, the first protection layer 11 may be formed on a surface of the metal layer 21, and then the second protection layer 31 may be formed on the other surface of the metal layer 21. Selectively, the second protection layer 31 may be formed on a surface of the metal layer 21, and then the first protection layer 11 may be formed on the other surface of the metal layer 21. As described above, the first protection layer 11 and the second protection layer 31 may be formed on the respective surfaces of the metal layer 21 by being coated or laminated. In the step S33 for forming the fabric layer 12, the fabric layer 12 may be arranged on the second protection layer 31 via the adhesive 13 and may be dried at the room temperature or may be pressed by using a press.
Referring to
For example, the outer battery casing 320 may comprise a fabric layer 322a, a metal layer 322b, and a first protection layer 322c like the composite films described above. The fabric layer 322a forms an outer packing casing of a battery, whereas the first protection layer 322c is a thermal fusing layer and forms an inner packing casing of the battery. If the sealing unit 324a is thermally fused when the outer casing main body 324 and the outer casing cover 322 closely contact each other, first protection layers (thermal fusing layers) of the sealing unit 324a are adhered to each other, and thus the outer battery casing is sealed. The composite films according to the various embodiments as described above, e.g., a film having a first protection layer/fabric layer structure, a film having a first protection layer/metal layer/second protection layer/fabric layer structure, etc., may be applied to the above-stated layer structure, where the descriptions given above may be referred to.
The electrode assembly 310 may be fabricated as a jelly-roll type assembly by winding a first electrode 312, a second electrode 314, and a separator 313 interposed therebetween or a plate-like stacked electrode assembly by stacking the first electrode 312, the separator 313, and the second electrode 314. The first electrode 312 and the second electrode 314 have polarities opposite to each other, and each of the first electrode 312 and the second electrode 314 may correspond to a positive electrode or a negative electrode. The first electrode 312 and the second electrode 314 include a current collector and an electrode active material applied onto at least one surface of the current collector, that is, a positive electrode active material or a negative electrode active material. Alternatively, the first electrode 312 and the second electrode 314 may have an electrode structure as disclosed in Korean Patent No. 1088073 filed by the present applicant on Oct. 16, 2010. However, the above-stated structures are merely examples, and the present invention is not limited thereto.
If the first electrode 312 of the second electrode 314 is used as a positive electrode, a current collector thereof may be formed of a stainless steel, nickel, aluminum, titanium, an alloy thereof, or aluminum or a stainless steel surface-treated by using carbon, nickel, titanium, or silver. Preferably, the current collector may be formed of aluminum or an aluminum alloy. If the first electrode 312 of the second electrode 314 is used as a negative electrode, a current collector thereof may be formed of a stainless steel, nickel, copper, titanium, an alloy thereof, or copper or a stainless steel surface-treated by using carbon, nickel, titanium, or silver. Preferably, the current collector may be formed of copper or a copper alloy
Generally, a positive electrode active material may be any one of lithium-containing transition metal oxides and lithium chalcogenide compounds, where the most popular examples thereof may be metal oxides including LiCoO2, LiNiO2, LiMnO2, LiMn2O4, or LiNi1-x-yCoxMyO2 (0=x=1, 0=y=1, 0=x+y=1, M is a metal, such as Al, Sr, Mg, and La). A negative electrode active material may be a carbon material, such as crystalline carbon, amorphous carbon, carbon complex, and carbon fibers, lithium, and a lithium alloy. The separator 313 prevents short-circuit between the first electrode 312 and the second electrode 314 and provides a path for lithium ion movements and may be a layer known in the art, e.g., a polyolefin-based polymer layer, such as polypropylene and polyethylene, or multi-layers, a micro-porous film, a woven fabric, and a non-woven fabric thereof.
A first electrode tab 315 and a second electrode tab 316 are attached to the first electrode 312 and the second electrode 314 of the electrode assembly 310 by being welded to the second electrode 314 and the second electrode 314 via laser welding, ultrasound welding, or resistant welding or by being adhered to the second electrode 314 and the second electrode 314 via a conductive adhesive to be electrically transmissive. The first electrode tab 315 and the second electrode tab 316 are formed to protrude from the electrode assembly 310 in directions in which the electrode assembly 310 is wound.
The first electrode tab 315 and the second electrode tab 316 of the electrode assembly 310 may be drawn via a sealing unit 324 a opposite to the side of line connected to the outer casing main body 324 and the outer casing cover 322 in the sealing unit 324a. Protective tapes 317 formed of an insulation material are attached to the electrode tabs 315 and 316 to prevent short-circuit therebetween.
Although not shown, a protection circuit module may be electrically connected to the first electrode tab 315 and the second electrode tab 316 to prevent overcharging and overdischarging of a battery and keep the battery from a dangerous state in the event of an external short-circuit. It should be understood that the outer battery casing and a battery employing the same are also included in embodiments of the present invention.
While the present invention has been particularly shown and described with reference to embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10-2014-0043206 | Apr 2014 | KR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/KR2015/003573 | 4/9/2015 | WO | 00 |
