High-Capacity Design for EV Batteries

Lithium-ion battery with improved fast charging capability and cycling performance. The battery has a specific viscosity range (1-6 mPa·s at 25°C) for the electrolyte solution and a specific ratio (1.05-1.5) between the lithium intercalation capacity of the negative electrode and the delithiation capacity of the positive electrode. This improves ion transport and provides more active sites for fast charging and cycling without capacity fade. The battery can further have a ternary positive electrode material (LiNixCoyQzM1-x-y-zO2) and a multi-layer negative electrode with separate layers on the current collector.

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Coated active material for batteries that reduces resistance degradation during cycling. The coated active material has a coating layer on the surface of the positive electrode active material. The coating contains a compound with a specific composition and carbon with a binding energy of 288.5±1.5 eV. This carbon comes from the coating material itself and is not an external contaminant. The coating composition and carbon binding energy can be adjusted to optimize resistance reduction. The coating material can also contain elements like niobium, nitrogen, sulfur, or phosphorus to improve lithium ion conductivity. The coated active material is made by coating the positive electrode material and treating it with carbonic acid to incorporate carbon into the coating.

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Positive electrode material for lithium-ion batteries that can maintain high capacity at high voltages. The material is a sodium-containing cobalt oxide with a chemical formula LixNa1-xCo1-zMzO2. During charge, the sodium-containing oxide undergoes a phase transition from an initial structure to a higher voltage structure. The key is that the initial phase transition releases more lithium ions than the final phase transition. This allows the material to extract more lithium at higher voltages, improving capacity, rate performance, and cycling life. The sodium-containing cobalt oxide has a positive electrode plate and battery structure.

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High-nickel, low-cobalt ternary positive electrode material for lithium-ion batteries with improved stability, capacity, and cycle life compared to existing materials. The material has a cobalt gradient distribution where the near-surface region has higher cobalt content. This is achieved by gradually adding cobalt during preparation instead of a coating step. The gradient cobalt prevents failure from coating detachment. The material also has reduced cation disorder and larger interlayer spacing for better rate performance.

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Positive electrode for high energy density lithium batteries with a dry processing method. The electrode uses a composite of large and small lithium iron phosphate particles along with polytetrafluoroethylene binder. This dry preparation method allows higher loading levels compared to wet methods. The combination of large and small iron phosphate particles improves adherence compared to using just one particle size. This enables higher energy density lithium batteries.

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Negative electrode for high-rate lithium-ion batteries with improved performance at high discharge rates. The negative electrode has a multilayer structure with a graphite-Si composite active material. The outer layer has lower tortuosity than the inner layer. This configuration provides better rate capabilities compared to a single-layer electrode with the same composition. The key is optimizing the tortuosity ratio between the layers and the Si content to balance graphite reaction kinetics and Si expansion.

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Negative electrode material for lithium-ion batteries with improved cycling performance. The material is graphite with specific properties before and after compaction. The specific surface area before compaction is X1 and after compaction is X2. The ratio (X2-X1)/orientation index before compaction is 0.05 to 0.5. This compaction process improves the material's dynamic performance during cycling. The compaction pressure is 0.5-10 Tons and duration 10-100 seconds. The compaction reduces the particle size and increases the surface area. The compaction also reduces the orientation index, making the graphite layers less ordered. This improves the lithium ion diffusion into the material during cycling.

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Secondary battery with improved energy density, dynamic performance, cycling performance, and storage performance. The battery has a negative electrode with a layered structure. The negative electrode film layer has two areas separated by 0.3 times the layer thickness. The first area near the current collector has a carbon-based material with pores greater than 0.15 μm2. The second area farther from the collector has a different carbon-based material without a coating. This design balances energy density, dynamic performance, cycling performance, and storage performance by utilizing pore structure in one area and avoiding coating in the other.

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A high-performance organic cathode material for lithium-ion and magnesium-ion batteries that overcomes the tradeoff between capacity and stability of traditional organic electrode materials. The cathode uses a polymer with helical perylene diimide subunits and the side-chains of the helical perylene diimide (hPDI) subunits are removed. This removes the leaching issue of organic electrode materials while maintaining high capacity. The cathode also shows improved rate capability and cycling stability compared to unmodified hPDI polymers.

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Cathode for solid-state lithium-ion batteries that reduces cracking and improves performance in solid-state batteries with ceramic separators. The cathode composition contains a fluorine-containing polymer with ionic groups. This polymer helps prevent cracking in the ceramic separator by providing intimate contact and minimizing volume changes during cycling. It also improves ionic conductivity between the cathode and separator. The cathode has a composition including: active cathode material, fluorine-containing polymer, optional second fluorine-containing polymer, and solvent.

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Electrochemical device like lithium-ion batteries with improved cycle life and reduced swelling by modifying the anode active material layer. The modification involves adding an auxiliary agent with specific properties to the anode active material. The auxiliary agent helps prevent defects like pinholes and pits during coating, improving cycle performance. It should have an oxidation potential >4.5 V, reduction potential <0.5 V, surface tension <30 mN/m, and content <3000 ppm in the anode layer. The electrolyte can also contain a low concentration of iron group elements like cobalt or nickel.

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A power storage cell design that prevents internal short circuiting by separating the cathode and anode terminals. The cell has a wound electrode inside a case with a lid. The lid has separate terminals for the cathode and anode. The cathode terminal is bonded to the case. This isolates the terminals to prevent contact and shorting. The cathode current collects through the case to the terminal.

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Battery pack design with increased energy density by using a perforated current collector between cells and conductive adhesive in the holes to electrically connect them. This reduces the number and size of current collectors compared to conventional packs, as well as eliminating a separate bonding layer. The perforated collector allows the cells to be stacked closely together with direct current flow between them. The adhesive fills the holes and electrically connects the cells to the collector.

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Sulfur-modified carbon material for improving the performance of platinum-carbon catalysts used in fuel cells and water electrolysis. The sulfur-modified carbon material has a higher sulfur content than the surface layer. This modification significantly enhances the catalytic activity and stability of platinum catalysts compared to using plain carbon. The platinum catalysts made with this sulfur-modified carbon have higher Pt 4f peak positions, lower Pt peak widths, and more internal Pt loading. This improves the catalyst's resistance to poisoning by sulfur, carbon monoxide, and hydrogen sulfide.

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Anticorrosion coating for acid electrolyte fuel cell components that provides long-term protection without significant cost increase or pollution compared to pure gold coatings. The coating is made of a tantalum nitride-based material doped with transition metals or lanthanides. The doped tantalum nitride layer prevents corrosion by forming a stable solid solution with the substrate. The coating can be multilayered with alternating doped and undoped tantalum nitride layers to further enhance crack resistance. This provides long-term corrosion protection for fuel cell components like bipolar plates and end plates without needing pure gold coatings.

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Integrated solid oxide fuel cell (SOFC) and turbomachinery system with high efficiency and reduced emissions. The system has a two-stage compression system with an electric motor driven low-pressure compressor and a high-pressure compressor driven by an expander. The SOFC exhaust is expanded in the expander. A heat exchanger lowers the exhaust temperature before expansion. This allows higher expander inlet temperatures. The system also has a combustor for unreacted fuel and oxidant. The expander drives the high-pressure compressor. The lower compression stage is electrically driven. The system provides higher efficiency than conventional power systems.

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Cooling multiple fuel cell systems on a vehicle using a common cooling system to avoid backflow issues. Each fuel cell system has a pump, and the flow rate and pump speed are controlled based on target flow requirements. This prevents backflow between cells when they operate at different rates. A model estimates pressures, flows, and temperatures to optimize pump speeds for each cell. A central controller coordinates the pump speeds and fluid flow control valves to balance cooling needs.

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Triple-doped bismuth oxide electrolyte for solid oxide fuel cells that has high ionic conductivity and stability at intermediate temperatures. The electrolyte is doped with erbium, yttrium, and zirconium in a specific composition range to stabilize the bismuth oxide structure and prevent phase transitions at lower temperatures. The triple doping reduces the total dopant content required compared to single doping. The optimized doping levels of erbium, yttrium, and zirconium allow the electrolyte to maintain the cubic fluorite structure even after 1100 hours at 600°C.

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Compact and reliable fuel cell stack design with improved reliability and easier maintenance. The stack has identical bipolar plates stacked head-to-tail, each with pockets at one end for measuring pins. The pockets open in the stacking direction. Consecutive bipolar plates have pockets facing opposite directions to limit deformation when pins are inserted. Spacers between plates provide wedging to prevent pocket distortion. This allows compact stack design without damaging pins. The stack also has features like membrane electrode assemblies recessed from the pocket openings and fins on the seals that are angled in the same direction for better flow management.

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A secondary battery design to prevent short circuits and improve electrolyte impregnation. The battery has insulating layers on the exposed current collector foil tabs of the cathode and anode plates, except for the tab combining sections. This prevents conductive contaminants from shorting the tabs during battery manufacturing. The insulating layers also prevent electrolyte leakage through the tab areas, improving impregnation of the wound electrode pack.

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