Coating Uniformity Methods for EV Batteries

A simple and efficient method to coat electrode materials for lithium-ion batteries to improve stability and cycle life. The method involves mixing the electrode material with a coating precursor like dicyandiamide or PVDF in a solvent, ball milling it, and then sintering to form a uniform coating layer on the electrode surface. This coating provides a stable interface and suppresses electrode reactions with the electrolyte to enhance battery performance.

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Battery design to improve energy density, safety, and flatness without increasing cell size. The battery has electrode sheets stacked inside a case. The positive electrode sheet size is increased compared to the negative sheet. This reduces the coverage margin of the negative sheet beyond the positive edge. The positive coating thickness is increased while keeping insulator thickness constant. This improves positive active material coverage. The second (negative) coating covers the first (positive) coating projection in thickness direction. The second coating edge is within the insulator. This prevents lithium precipitation at edges. The reduced edge thickness difference improves surface flatness.

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Method for manufacturing anode for lithium secondary battery that allows polymer deposition even inside the anode mixture layer to prevent cracking and improve durability. The anode is formed by applying a lithium composite transition metal oxide slurry on a current collector, then polymer coating using iCVD at substrate temperatures above 100°C. This allows uniform polymer distribution inside the anode's lower porosity compared to other electrodes.

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A method for producing battery electrodes that reduces layer thickness variation and prevents cracking during drying. The method involves coating the current collector with a viscous raw layer containing an activated adhesive starting component. This component is stabilized to form an adhesive before drying. The adhesive stabilizes the raw layer locally to prevent material flow and thickness variations during drying. This prevents cracking and ensures consistent electrode thickness. The activated adhesive can be a monomer that polymerizes into a long-chain adhesive during stabilization.

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Method for manufacturing battery electrodes with improved flatness and reduced thickness variation of the active material layer. The key is coating the electrode slurry at a speed that exceeds the yield point of the slurry. The slurry has specific flow properties with a region where shear stress is constant and a region where shear stress increases with speed but at decreasing rate. Coating at speeds exceeding the yield point prevents sagging and improves layer uniformity.

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A preparation method for cathode material for lithium-ion batteries with uniform and conductive coating layers that improves cycle life and capacity retention. The method involves steps like mixing precursor powder, primary sintering, coating with modified binder, and secondary calcination. The binder is treated to optimize coating properties. The precursor powder is prepared by complex co-precipitation to form NCM313 particles. The coating agent is applied at a specific concentration. The modified binder treatment improves coating uniformity and conductivity compared to standard binder. The secondary calcination step refines the particles and coating. This results in cathode material with uniform coating layers, better conductivity, and improved cycle life and capacity retention.

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Battery design with a specialized pole piece and coating configuration to improve battery performance and longevity, especially in cylindrical lithium-ion batteries. The pole piece has a unique coating profile where the mass per area of the positive electrode coating increases progressively along the pole piece length, while the negative electrode coating decreases. This compensates for the inherent difference in coating mass between inner and outer pole piece segments during winding. This keeps the positive/negative coating ratio stable throughout the battery construction to prevent issues like local lithium precipitation, improve charging, cycle life, and safety.

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Coating battery electrodes with artificial solid electrolyte interfaces (SEI) to improve safety and thermal stability of batteries. The artificial SEI is formed by a liquid phase deposition process that involves exposing the electrode to reactant solutions in chambers and rinsing between chambers. The coating provides protective barrier on electrode surfaces to prevent exothermic reactions, reduce gas evolution, and raise thermal runaway onset temperatures compared to uncoated electrodes.

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Partially coating lithium-ion battery cathode active materials with a thin layer of acidic alumina to reduce resistance build-up during cycling. The process involves reacting the active material with a zirconium alkoxide or amide to form a precursor. This precursor is then mixed with water and the active material to coat the particles. The coated material is dried and further mixed to homogenize the coating. The coating provides a protective barrier on the active material surface that prevents unwanted reactions during cycling, reducing resistance and improving cycle life.

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A production process for new energy batteries that improves battery quality and reduces issues like electrode thickness variation, sealing problems, and electrolyte leakage. The process involves using specific materials and steps for each battery component. The positive electrode is made by coating the active material onto aluminum foil. The negative electrode uses cladding on copper sheets. The electrolyte is a mixed solvent with ammonium salt or lithium salt. The diaphragm is a microporous membrane. This combination helps ensure consistent electrode thickness, better sealing, and prevent electrolyte leakage in the battery.

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Double-layer coating structure for battery cells and winding battery cells that improves performance and reliability. The coating structure has a bottom layer between the current collector and surface layer. This bottom layer provides additional protection against electrolyte penetration and improves cell longevity. The surface layer contacts the separator and helps prevent separator puncture. This double-layer coating can be used on both positive and negative electrodes.

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Preparing lithium-ion battery positive electrode materials with improved cycle life and stability by coating them using a fatty acid salt. The method involves mixing a metal salt of a C10-C34 fatty acid with the positive electrode material and sintering it at temperatures between 200-1000°C for 1-24 hours. This solid-phase reaction disperses the metal oxide coatings uniformly on the electrode surface, reducing the amount needed compared to conventional coatings. The fatty acid salt coating improves cycle life, energy retention, and resistance compared to uncoated materials.

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Lithium-ion secondary battery with improved cycle life by controlling the current flow within the battery cell to prevent localized deterioration. The battery design features a coating on the edges of the positive and negative electrodes that guides the electron flow toward the corners. This prevents concentration of current in the center and reduces localized degradation.

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Preparation method for electrode pole pieces of lithium-ion batteries with improved uniformity of conductive agent distribution to enhance high-rate discharge performance. The method involves multi-layer coating and drying of the electrode slurry instead of a single coating step. The coating is repeated multiple times to build up the electrode layer. This provides a more uniform distribution of conductive agents inside the pole piece compared to a single coating. The number of coating iterations can be adjusted to optimize performance.

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Coating method for ternary positive electrodes in lithium-ion batteries that improves cycle life and capacity by using vacuum evaporation instead of mechanical mixing. The method involves placing a target material on an evaporation boat inside a vacuum chamber, heating it to evaporate the material onto the electrode surface. This provides a uniform, compact coating without particle size issues. The vacuum environment prevents particle agglomeration and ensures the coating adheres well to the electrode.

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Preparing a lithium battery with improved storage life and safety by coating the cathode with a multilayer oxide coating. The coating consists of nano alumina, zirconia, and a conductive agent. The thickness is 5-8 microns. This coating on the cathode reduces dendrite growth on the lithium metal anode during cycling, preventing short circuits and capacity fade.

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Lithium-ion battery with improved energy density by optimizing the coating thickness and particle orientation of the electrode active materials. The single-side coating density of the positive electrode is 23-50 mg/cm2 and negative electrode is 14-30 mg/cm2. The positive active material particles are consistently arranged and oriented with an angle <=30 degrees to the electrode thickness. This reduces ionic resistance and improves capacity compared to thicker coatings with disoriented particles.

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Method for manufacturing secondary batteries like lithium-ion batteries and solid-state batteries with improved performance and throughput by using a solvent system with a low boiling point solvent and supercritical carbon dioxide (SCF) instead of traditional high boiling point solvents. The SCF is merged with the slurry upstream of the coating head and applied to the electrode substrate using airless spraying. This allows high solid content, high viscosity slurries to be applied without settling issues. The SCF expands after spraying to push out residual slurry. The low boiling point solvent evaporates quickly, reducing drying time and residual solvent.

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Battery with improved low temperature charge-discharge performance by optimizing the thickness, particle size, and electrolyte viscosity of the coatings on the positive electrode. The coating layers on the positive electrode surface are the first coating and second coating. The battery satisfies a specific relation between the thickness, particle size, and electrolyte viscosity of the coatings: eta * T1 / (D501 * D502) > 5, where eta is electrolyte viscosity, T1 is first coating thickness, D501 is first coating median particle size, T2 is second coating thickness, D502 is second coating median particle size. This relation reduces the lithium ion diffusion distance in the solid phase to improve direct current resistance at low temperature charge states. It also balances performance tradeoffs between viscosity, particle size

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Lithium ion battery with improved energy density and safety through surface coating modification using magnetron sputtering. The battery has a nanoprotective layer on the electrode surfaces and the current collector areas. The nanoprotective layer is 10-200 nm thick and prevents electrolyte ingress during needle puncture. It allows higher energy density without thickening separators or adding flame retardants. The nanoprotective layer is deposited by magnetron sputtering on the electrode and current collector areas during winding. This enables uniform coating of both electrode surfaces regardless of spacing.

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Coating process for thick film lithium batteries with higher energy density and improved safety compared to conventional lithium-ion batteries. The coating process involves multiple layers on the battery electrode. The layers are applied in sequence: (1) a surface active layer, (2) a pre-coating layer, (3) a working layer. The surface active layer helps prevent cracking during coating, allowing higher loading capacity. The pre-coating layer bonds with the current collector. The working layer contains the active material. This multi-layer coating enables thicker electrodes with higher energy density while preventing cracking and delamination issues.

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Coating and drying process for lithium-ion battery electrodes that improves performance and reduces costs. The process involves staged gradient temperature drying: initial drying at lower temperatures, then higher temperatures, and finally constant temperature drying. This prevents solvent migration during drying that can lead to uneven coating composition and bonding issues. The process reduces composition and thickness non-uniformities compared to rapid drying. It also allows lower energy consumption by avoiding excessive temperatures.

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Manufacturing multilayer electrodes for secondary batteries with improved uniformity and prevention of slurry leakage. The process involves applying two slurries with different viscosities on the electrode current collector with through holes. The first slurry, with higher viscosity, is applied first to prevent leakage. The second slurry, with lower viscosity, is then applied on top. This allows forming a uniform electrode mixture layer without slurry leakage through the holes.

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Preparation method for electrodes with uniform pore structure to improve cycle life of lithium-ion batteries. The method involves coating the electrode active material in layers with progressively smaller particle size electrode active material closer to the current collector. This prevents large pores forming in the outer layers during drying and baking that can lead to uneven electrolyte storage and capacity loss. By selecting particle sizes based on layer position, all layers have similar pore characteristics and electrolyte retention.

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Method to prepare coated cathode active materials for lithium-ion batteries with reduced resistance buildup during cycling without sacrificing overall electrochemical performance. The method involves treating the active material with compounds like carbonyls, amides, alkoxylates, and halides to coat the surface. The coated material is then calcined at moderate temperatures. The coating thickness is 0.1-50 nm. This provides a protective barrier that prevents surface reactions and resistance growth without hindering lithium ion transport.

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A method to prepare high areal density electrodes for batteries and capacitors that uses a unique slurry preparation and coating process. The method involves preparing a slurry with a viscosity of 1000 mPa·s at 20°C, containing the active material, conductive additive, and binder. The slurry is then subjected to high pressure (0.1-0.8 MPa) to compact the particles. This densified slurry is then coated onto the current collector using a doctor blade or similar technique. The high viscosity slurry prevents sedimentation and phase separation during drying, allowing thicker coatings and higher areal density electrodes without cracking or powder drop.

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Preventing lithium precipitation in square winding lithium-ion battery cells to improve cycle life and safety by selectively increasing coating density on the side surfaces of the negative electrode compared to the top and bottom surfaces. This compensates for the higher lithium intercalation strain on the curved side edges of the square winding shape, reducing the risk of lithium plating and short circuits.

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Method of manufacturing lithium battery electrodes with improved output characteristics by coating the electrode active material slurry in zones on the current collector. The coating process involves dividing the width of the current collector into three or more zones and coating the slurry separately in each zone. The energy loading per unit area is higher at the end zones compared to the middle zone to prevent local current flow and load issues. The end zone loading can be 1-3 times or 1-1.5 times the middle zone loading. This allows uniform loading across the electrode width and prevents thinning at the edges.

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Method for manufacturing a battery cell with improved performance by coating the anode and/or cathode with a porous, insulating layer. The layer is applied by spraying or vapor deposition. After wetting with electrolyte, the coating becomes ionically conductive. This prevents internal shorts while still allowing ion transport. The coated electrodes are used to create the battery cell.

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Continuous manufacturing method for lithium secondary batteries with improved lifespan and charge-discharge efficiency. The method involves forming a uniform passivation film on the lithium metal anode before assembling the battery. This is done by coating the lithium anode with a specific electrolyte solution containing additives favorable for passivation film formation. After coating, the anode is dried and then assembled into the battery using a separate electrolyte solution for injection. This prevents additives in the injection solution from affecting battery performance while still forming a uniform passivation layer on the anode surface.

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Lithium-ion battery composite electrode with improved performance and coating method for making it. The composite electrode has a three-layer structure with a transition zone between the top and bottom layers. The layers are the top coat, transition zone, and bottom layer. The coating method involves using a synchronous coating process where the solvent gradually volatilizes as the layers are applied. This prevents cracking and peeling. The layers have good interfacial bonding to avoid delamination. The transition zone density promotes ion diffusion. The composite electrode has improved power, rate, and cycle life compared to conventional electrodes. The coating unit has spray equipment and a drying unit for applying the layers.

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A lithium battery design with coatings on the electrode tabs and separators to improve battery life and safety. The coatings are made of a ceramic material containing boehmite. The coatings on the electrode tabs prevent dendrite growth and short circuits by providing a barrier between the tabs and the electrolyte. The coatings on the separators between the electrodes prevent dendrite punctures and short circuits. The ceramic coatings also prevent corrosion of the electrode materials. The coatings are applied using techniques like printing or spraying.

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Simplified and efficient method for manufacturing electrodes for lithium-ion batteries that avoids issues like non-uniform coating and delamination. The method involves mixing a paste-type slurry with 70-90% solid content directly onto the current collector, then rolling the slurry-coated collector to form the electrode layer. This eliminates the need for separate drying steps between coating and rolling. The rolling also forms the electrode layer without wrinkles or curling. The slurry solids content is higher than conventional coatings to enable direct rolling without drying.

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Coating method for lithium battery electrode materials that provides uniform and thin coatings without using solvents or complexing agents. The method involves grinding a slurry of coating material with a specific viscosity and particle size, then stirring and mixing it with the electrode material to form a slurry with a higher viscosity. The slurry is dried and fumigated to obtain the coated electrode material. The coating provides improved electrical properties like capacity and cycle life for the lithium battery electrodes.

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A cylindrical battery with improved cycle performance and efficient material utilization. The battery has a unique pole piece structure that addresses the limitations of conventional cylindrical battery designs. The pole piece is made with a specific texture and coating configuration to improve cycle life and prevent capacity imbalance. This involves using a two-coat structure with different thicknesses on the pole piece surface. The coating composition may include materials like fluoride, PVDF, PTFE, or SBR rubber. The two coats have identical components but differ in thickness. This design prevents capacity variation and improves cycle performance compared to conventional pole piece coatings.

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Thin film battery with improved cycle life and high capacity density. The battery is made by depositing an active material on a substrate, annealing it at a low temperature in oxygen to form a precursor with small crystals, then rapid annealing at a higher temperature in oxygen to form the final active material coating layer with uniform small crystals. This two-stage annealing process improves cycle life by preventing cracking and dendrite formation in the electrolyte. The battery can also have protruding electrodes and current collector bumps to enhance performance.

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Electrode for high capacity lithium secondary batteries with improved structural stability, uniformity, and conductivity. The electrode consists of two coating layers. The first layer has a linear conductive material and binder. The second layer has the active material and binder. Applying the first layer with linear conductive material on the current collector shapes the electrode structure. Then adding the second layer with active material fills in the gaps. This two-step process ensures uniformity, stability, and conductivity compared to direct active material coating.

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Coating method for lithium-ion battery electrodes that allows layering of different active materials to optimize performance. The method involves separately preparing multiple active slurries, each containing a different active material, and then coating them sequentially on the same current collector. After drying, this results in an electrode with multiple active paste layers. The layering allows combining the benefits of multiple materials without blending them together.

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A dual coating method for battery electrodes to prevent cracks in circular battery cells during winding while maintaining battery performance. The method involves coating the electrode twice, with a different slurry for the second coat. The first coat is applied at a lower thickness to the core area where cracks are less likely. The second coat is applied to the rest of the electrode. This allows optimized coating for each area. The first coat has good adhesion to the metal collector, while the second coat has good adhesion to the first coat. This efficiently utilizes the slurry properties for stability and performance.

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A method to improve the performance of lithium-ion batteries by coating the electrode material with a polymer to enhance cycle life, capacity retention, and safety. The coating process involves dissolving a fluorine or chlorine-containing polyolefin in a solvent, impregnating the electrode material, and heat treating in vacuum or inert gas to form a thin, dense polymer layer. This coating reduces active material pulverization during expansion/contraction, promotes SEI film formation, and blocks electrolyte decomposition. The fluorine/chlorine groups in the polymer also contribute to SEI film formation.

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Method to improve cycle life and storage stability of lithium-ion batteries by coating a thin layer on the surface of the positive electrode. The coating contains a particulate acrylic polymer, a water-soluble polymer, and water. The coating ratio is 60-95% of the solid content. Applying this coating on the positive electrode after forming the electrode layer improves high temperature cycling and storage performance compared to dispersing the polymers in the electrode mix.

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Method for manufacturing lithium-ion batteries with improved reliability and performance. The method involves coating an electrode material on a current collector followed by heating to gel the electrode coating. Then, an insulating material containing a gelling agent is applied and heated to gel the interface. This prevents active material mixing into the insulating layer. The gelled electrode and insulating layers are dried to form the electrode and separator. This avoids thinning the separator and shorting between electrodes.

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Efficiently forming a smooth protective layer on the surface of an active material layer in a power storage device electrode without impairing leveling properties. The method involves applying a protective coating slurry to the active material layer and then heating it using dielectric heating. The active material itself generates heat due to dielectric properties, allowing efficient drying without needing to heat the current collector. This prevents film formation and enables smooth protective layer formation on the active material surface.

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Method for preparing a coating-type electrode material for lithium-ion batteries with improved stability and cycle life. The method involves vapor coating of the electrode material using reagents like silicon compounds. The coating prevents direct contact with the electrolyte, improving stability. The coating is applied by reacting the electrode material and coating reagents in a furnace at elevated temperatures. The reagents vaporize and coat the electrode material without direct contact. This enables precise control over coating thickness and properties compared to methods like ball milling or immersion coating.

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A method for manufacturing battery electrodes that improves adhesion and prevents peeling off of the coating from the current collector. The method involves applying a slurry with a solid content of 65-85% when coating the electrode. This high solid content reduces segregation and migration during drying, preventing concentration gradients that weaken adhesion. Coating both sides of the electrode base material also helps prevent warping during drying.

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Controlling the thickness and profile of coated film edges to improve coating uniformity and prevent issues like tapering and edge effects. An edge material is coated adjacent to the main coating material to augment or reshape the edge. This provides a more uniform and consistent edge thickness profile. The edge material can also have specific functions like insulation or barrier properties. The edge coating contacts and seals with the main coating material edge.

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Electrode assembly and secondary battery with balanced coating areas on the positive and negative electrodes. This is achieved by ensuring the area of the positive electrode coating is the same as or greater than the negative electrode coating within a tolerance range. By balancing the coating areas, it helps prevent uneven expansion and contraction during charge/discharge cycles, which reduces cracking and separation of the electrode stack.

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Non-aqueous electrolyte secondary battery with improved discharge characteristics and energy density by optimizing thickness of electrode coatings on both sides. The battery has a wound stack with separator between positive and negative electrodes. On each electrode, the thickness of the coating layer on one side is different from the other side. This allows thicker coatings on some surfaces to improve performance while maintaining balance overall. The thicker coatings could potentially have higher active material loading, lower internal resistance, or better rate capability compared to thinner coatings.

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Method to improve safety, capacity, and cycle life of square lithium ion batteries by coating the negative electrode surface with an inorganic oxide layer. The coating is applied by mixing the inorganic oxide and binding agent, then applying it to the negative electrode surface and drying it. This creates a dense oxide layer on the negative terminal that prevents dendrite growth and short circuits compared to the thin barrier film between positive and negative electrodes.

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Lithium secondary battery with improved capacity and longevity by using a simple coating technique on the electrodes and separator. The coating is a layer of alkali metal like lithium. This alkali metal coating reduces irreversible capacity losses during cycling and prevents dendrite formation compared to uncoated batteries. The coating is formed by depositing alkali metal particles onto the electrode and separator surfaces during battery assembly. The coating concentration is adjusted to occlude and react with the irreversible capacity without excess waste.

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