Polymer battery module packaging sheet and a method of manufacturing the same

Abstract

A polymer battery module packaging sheet includes, as essential components, a base layer ( 61 ), an aluminum layer ( 62 ), chemical conversion coatings ( 64 a , 64 b ) coating the opposite surfaces of the aluminum layer ( 62 ), and an innermost layer ( 63 ). The chemical conversion coatings ( 64 a , 64 b ) 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 ( 64 a , 64 b ) of the aluminum layer ( 62 ) with adhesive layers ( 65 a , 65 b ), respectively.

What is claimed is: 
     
         1 . A polymer battery module packaging sheet for forming an embossed type packaging comprising:
 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.   
     
     
         2 . 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. 
     
     
         3 . The polymer battery module packaging sheet according to  claim 2 , 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. 
     
     
         4 . 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. 
     
     
         5 . The polymer battery module packaging sheet according to  claim 3 , wherein the cast polypropylene heat-sealable resin layer is formed of an ethylene-propylene copolymer resin. 
     
     
         6 . The polymer battery module packaging sheet according to  claim 1 , wherein the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. 
     
     
         7 . The polymer battery module packaging sheet according to  claim 3 , wherein the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. 
     
     
         8 . 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. 
     
     
         9 . The polymer battery module packaging sheet according to  claim 3 , 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. 
     
     
         10 . 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. 
     
     
         11 . 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. 
     
     
         12 . The polymer battery module packaging sheet according to  claim 4 , wherein the ethylene-propylene copolymer resin is ethylene-rich-random polypropylene resin. 
     
     
         13 . The polymer battery module packaging sheet according to  claim 1 , wherein the aluminum layer covers an entire surface of the oriented nylon film. 
     
     
         14 . A polymer battery module packaging sheet for forming an embossed type packaging comprising:
 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.   
     
     
         15 . 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. 
     
     
         16 . The polymer battery module packaging sheet according to  claim 15 , 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. 
     
     
         17 . 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. 
     
     
         18 . The polymer battery module packaging sheet according to  claim 16 , wherein the cast polypropylene heat-sealable resin layer is formed of an ethylene-propylene copolymer resin. 
     
     
         19 . 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. 
     
     
         20 . The polymer battery module packaging sheet according to  claim 16 , wherein the adhesive layer and the heat-sealable resin layer are formed by a sandwich lamination method. 
     
     
         21 . 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. 
     
     
         22 . The polymer battery module packaging sheet according to  claim 16 , 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. 
     
     
         23 . 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. 
     
     
         24 . 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. 
     
     
         25 . The polymer battery module packaging sheet according to  claim 17 , wherein the ethylene-propylene copolymer resin is ethylene-rich-random polypropylene resin. 
     
     
         26 . The polymer battery module packaging sheet according to  claim 14 , wherein the aluminum layer covers an entire surface of the oriented nylon film.