Low-cost, flexible battery packaging materials

Considerable cost savings can be realized if the metal container used for lithium-based batteries is replaced with a flexible multi-laminate containment commonly used in the food packaging industry. This laminate structure must have air, moisture, and electrolyte barrier capabilities, be resistant to hydrogen-fluoride attack, and be heat-sealable. After extensive screening of commercial films, the polyethylene and polypropylene classes of polymers were found to have an adequate combination of mechanical, permeation, and seal-strength properties. The search for a better film and adhesive is ongoing.