Enhancing EV Battery Coating Uniformity for Improved Performance

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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Electrode design for lithium-ion batteries that prevents short circuits and improves battery life. The electrode has a coating at the edge that contacts the side surface of the electrode portion and extends to contact the insulating layer. This coating prevents short circuits if the electrode deforms during battery assembly. It also minimizes side reactions between the electrode and electrolyte, reducing capacity loss. The coating has a first region contacting the electrode edge and a second region extending onto the insulating layer. The coating thicknesses and compositions are optimized for insulation, adhesion, and heat resistance.

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Lithium-ion battery with improved safety and energy density. The battery has a modified positive electrode plate with a safety primer coating on the current collector. This coating reduces short circuiting between the negative electrode and the aluminum current collector. The electrolyte composition is optimized to improve wetting, capacity retention, and coating density. The electrolyte contains propyl propionate and fluorobenzene. This allows better uniform electrolyte penetration and reduces impedance compared to conventional electrolytes. The coating composition and electrolyte formulation balance improves safety, wetting, and capacity retention while maintaining energy density.

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Battery pole piece design and manufacturing method to improve battery performance by enabling better electrolyte flow, preventing electrolyte channel clogging, and reducing expansion issues. The pole piece has a coated region with higher coating density compared to an uncoated region. This creates a channel for electrolyte diversion through the coating-free area. The channel allows electrolyte to bypass thicker regions and flow around the pole piece during expansion, preventing electrolyte trapping and channel clogging. The coating density difference and channel design improve battery performance by enabling better electrolyte flow, preventing electrolyte channel clogging, and reducing expansion issues.

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Battery design to improve initial efficiency and prevent lithium precipitation at circular arc regions. The battery has a pole piece or separator partitioned into planar and arc areas. In the planar regions, a coating with a higher lithium supplementing agent content is used. This improves initial battery efficiency. In the arc regions, the lithium supplementing agent content is lower to prevent lithium precipitation.

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Electrochemical devices like batteries with improved flatness, liquid retention, and safety. The devices have an electrode assembly with a composite layer on the current collector. This composite layer has a functional layer between the collector and insulating layer. The functional layer absorbs electrolyte and prevents uneven electrolyte distribution. The insulating layer prevents internal shorts. The functional layer thickness is 1-20x the insulating layer thickness to balance liquid retention and flatness vs safety. This configuration improves device appearance, reduces energy density loss, and prevents internal shorts.

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Electrode design and assembly for lithium-ion batteries that improves safety, thermal stability, and performance. The electrode has a current collector, electrode mixture layer, and functional coating on the other side. The coating can include a heat resistance layer and/or a conductive layer with higher conductivity than the collector. The outermost electrode can also have improved conductivity. The coating and outermost electrode enhance safety by reducing thermal runaway propagation and improving stability from fire and heat. The higher conductivity electrodes also improve battery performance.

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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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Electrochemical cell with improved energy density compared to conventional cells. The cell has a wound pole piece design with an active material layer on each surface. The active material layer on one side has an extended edge coating that overlaps and adjoins the main coating. This reduces expansion and thinning of the active material at the edge during cycling. The extended edge coating also helps prevent shrinkage at the ends of the pole piece. This increases the thickness of the active material at the edges, which improves energy density.

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Electrode pole piece for lithium-ion batteries that improves charge transfer efficiency and cycle life. The pole piece has two coatings with lower OI (intercalation) value for the second coating compared to the first. This avoids excessive thickness increase and charge transfer path lengthening from thick coatings. The lower OI second coating helps reduce charge transfer resistance. The ratio of OI values (OI1/OI2) should be between 1.1 and 2.0.

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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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A lithium battery preparation process that improves battery performance by inhibiting electrolyte decomposition on the positive electrode. The process involves coating a primary active material layer on a foil substrate, then coating a secondary layer containing a ternary material on top. This reduces the contact area between the primary layer and electrolyte, preventing electrolyte decomposition on the primary layer. The multi-layer positive electrode improves high-temperature stability and cycle life compared to a single layer.

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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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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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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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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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Lithium ion battery with reduced expansion during cycling to improve long-term reliability without sacrificing energy density. The battery has a multilayer electrode with two coatings on the current collector. The outer coating has lower specific capacity and lower initial coulombic efficiency than the inner coating. This gradient distribution of active sites reduces expansion during cycling compared to uniform high capacity coatings. The battery also has a separator, electrolyte, and cathode/anode selected for long-term reliability.

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