High-Capacity Design for EV Batteries

Manufacturing lithium secondary batteries with enhanced capacity retention and reduced gas generation through controlled activation. The method employs constant current charging until the charge cut-off voltage, followed by constant voltage charging. This approach prevents premature activation of the lithium-rich manganese-based oxide (LiMn2O3) phase during activation, which typically leads to abnormal capacity behavior and gas generation. The activation process is performed under pressurization conditions to minimize non-activated Li2MnO3 phase formation and prevent lithium precipitation.

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Layout of a battery system in an electric vehicle to increase storage capacity without sacrificing space inside the main cabin. The vehicle has two battery housings, one on each side of the vehicle, that overlap and are offset in the front-rear direction. This allows more batteries to be housed outside the cabin compared to just having a single battery pack under the seat. It also provides some visual benefits by improving forward visibility for the driver due to the front-rear offset and angled upper housing.

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Rechargeable lithium battery with improved cycle life and capacity by using a specific composition of particle sizes in the positive electrode. The electrode contains small 1-8 um monolithic particles and larger 10-20 um secondary particles, both containing nickel-based lithium oxide. This mixture with a density over 3.4 g/cc has an X-ray diffraction peak intensity ratio over 3. It provides high capacity and cycle life by reducing side reactions, improving efficiency and temperature stability.

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Silicon carbon composite for high-performance negative electrodes in lithium-ion batteries. The composite has a specific ratio of peak intensities in a 29Si NMR spectrum. The ratio is 1.3-4, where peaks A, B, and C represent chemical shifts of 20-15 ppm, -20 to -100 ppm, and -110 to -140 ppm, respectively. The composite is formed by heat treating silicon oxide, etching, pulverizing, and reacting with carbon. This composition provides improved capacity, efficiency, and water-based processability compared to silicon-carbon composites without the specific NMR peak ratio.

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Battery architecture for long duration energy storage (LODES) applications that allows operation at high capacity and low self-discharge rates. The batteries have open cell designs where the electrolyte separates the metal and air electrodes. This prevents direct contact between the metal and oxygen in sealed batteries. The electrolyte also has low oxygen solubility and carbonate levels. This prevents parasitic discharge of the metal electrode and oxygen barrier. The metal electrode can be submerged or removed from the electrolyte using pumps, bladders, or lifts to balance capacity and self-discharge.

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A rechargeable lithium battery with improved cycling performance and capacity retention. The battery uses a unique negative electrode active material composition. It combines rod-shaped artificial graphite with a specific diameter and aspect ratio, along with a silicon-carbon composite. This mixture provides a balance between capacity and cycling stability compared to using just the graphite or just the silicon-carbon composite. The rod-shaped graphite improves cycling stability while the silicon-carbon composite provides capacity.

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Electric vehicle structure that increases range by maximizing battery capacity while minimizing weight and maintaining crashworthiness. The structure uses integrated battery modules and cross members to pack more batteries without adding much body weight. The design involves side sills, a floor panel, a battery tray, an integrated-battery front cross member, and a dash cross member. The integrated-battery front cross member connects the battery tray and front of the floor panel to form a continuous frame. This allows stacking more batteries in the tray without increasing body weight. The dash cross member connects the floor and front of the integrated-battery member. This provides crash protection while enabling more batteries in the front. The integrated battery frame and cross members distribute forces to the body and side sills, allowing more battery capacity.

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Battery packs for metal-air batteries that enable higher voltage and capacity through dynamic switching between series and parallel configurations. The pack comprises air channels, electrolyte channels, and electronic circuitry to manage the battery cells. The circuitry dynamically switches between series and parallel connections for the individual cells, enabling voltage increases while maintaining capacity. The pack also incorporates air intake and output systems to maintain ambient oxygen levels. This configuration allows for battery packs with multiple voltage levels, enabling applications beyond simple battery packs.

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Carbonaceous material, production method, electrode active material, electrode, and electrochemical device for high performance electrochemical devices like batteries and capacitors. The carbonaceous material has a specific surface area of 1550-2500 m2/g, oxygen/hydrogen content of 1.00-2.10 mg/m2, and electrical conductivity of 10-15 S/cm. The production involves heating the precursor to 330°C under oxygen, then cooling under inert gas to reduce surface oxygen. This prevents pore shrinkage while reducing intra-skeletal oxygen. The final heat treatment under oxygen is critical, followed by cooling under inert gas. The resulting carbon has high capacitance, gas suppression, and durability.

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A layout for an electrical power supply system in a vehicle that increases battery capacity without taking up more space inside the vehicle. The layout involves having separate battery housings, one on each side of the vehicle, that partially overlap. This allows multiple battery modules in each housing to be arranged in groups. By having separate housings that can be spaced apart, it's possible to fit more battery capacity compared to if all the batteries had to be inside the main vehicle body.

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In-vehicle electric power storage system with parallel coupled high-capacity and high-output batteries, allowing stable battery outputting. The high-capacity battery set has higher capacity but lower output than the high-output set. When the high-capacity battery voltage drops close to a threshold, it is disconnected and the high-output battery continues powering. This prevents sudden output drops when switching between batteries.

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Method to produce partially reacted silicon layers for lithium batteries with controlled lithium intercalation capacity. The method involves depositing a thin layer of silicon on a substrate, followed by accelerated annealing to partially react the silicon with the substrate metal. This process is repeated multiple times to build up a multi-stratum structure of partially reacted silicon. By controlling the annealing conditions and adding metal to each layer, the resulting anode has a gradual transition from silicon to silicide with high capacity silicon near the surface and stable adhesion near the substrate.

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Battery module design that allows increasing battery capacity without significantly increasing height. The module has two cell sets stacked back-to-back, with poles extending laterally. A central connector assembly (CCS) runs around the perimeter of the cell sets, extending in the stacking direction. It connects the cells electrically, allows temperature and voltage monitoring, and replaces the need for stacking more cells vertically. This reduces height compared to stacking more cells.

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A lithium-ion battery electrode material with enhanced performance and cost-effectiveness. The material is a lithiated spinel-layered composite with a specific capacity of 200Ah, high cycle stability, and low cost. The material achieves these properties through a novel spinel structure with optimized lattice parameters and a tailored composition. The spinel structure enables improved electrochemical performance, while the precise composition and processing conditions enable significant cost reductions. The material's performance is validated through specific capacity retention, rate capacity, and voltage stability tests, demonstrating superior capacity retention compared to conventional materials.

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Positive electrode for a solid-state battery with high energy density and low internal resistance. The positive electrode has a composition and structure that allows it to provide high capacity and output while suppressing internal resistance. The positive electrode active material is a lithium-rich nickel-rich oxide like LiNi1-x-yMxO2. This high-Ni oxide improves cycle stability and energy density. The electrode also uses a thin positive electrode active material layer, a binder with low particle size, and a solid electrolyte with high lithium ion conductivity. These factors reduce the internal resistance while maintaining high energy density.

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Preparing high-performance negative electrode material for lithium-ion batteries that improves initial discharge capacity, initial efficiency, and cycle life compared to conventional silicon-based materials. The method involves coating a pitch binder on spherical silicon-carbon composite particles. The silicon particles are first mixed with an organic resin and dried to form spherical powders. Then, a pitch solution is applied and the particles are carbonized. This uniformly and densely coats the pitch on the silicon surface, preventing volume expansion and structural destruction during cycling. The pitch-coated silicon-carbon composite has better initial discharge capacity, initial efficiency, and cycle life compared to uncoated silicon composites.

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Anode-free rechargeable lithium battery design for electric vehicles that avoids the safety and cost issues of traditional anode materials. The battery uses an "anode-free" cell configuration where the anode is eliminated and replaced with a pre-lithiated cathode material that provides lithium ions. The cathode material is a lithiated spinel oxide like Li1+xMn2O4. The negative electrode has a current collector but no active material. The non-flammable electrolyte conducts lithium ions between the electrodes. This allows higher capacity, lower cost, and safer batteries for electric vehicles compared to conventional lithium-ion cells with graphite anodes.

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Layout of an electrical power supply system for a vehicle that increases the storage capacity of batteries compared to conventional designs. The vehicle has multiple separate battery housings, some of which overlap, located in different positions in the vehicle body. This allows maximizing the battery capacity without sacrificing space for other components. The overlapping housings share some volume to further optimize utilization. The layout improves battery capacity compared to a single enclosure between the front wheels, which is limited by wheel turn radius. The separate housings can also be spaced apart for better cooling and easier access.

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Graphite-based lithium-ion battery electrodes with enhanced capacity retention through controlled volume changes during charge/discharge cycles. The electrodes contain silicon and/or other high-capacity materials with atomically dispersed inert elements, such as carbon, oxygen, and halogens, which act as mechanical buffers and support structures during lithiation. The inert elements are chemically dispersed throughout the silicon matrix, forming a single-phase structure that maintains structural integrity and prevents pulverization during cycling. This approach enables the integration of high-capacity materials into electrodes while preserving the integrity of the electrode layers.

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Solid-state battery with improved anode materials for higher capacity and longer life compared to conventional lithium-ion batteries. The battery uses an anode with layers of tin metal and silicon/silicon-based materials instead of the typical composite of silicon particles. This configuration provides better performance because it reduces capacity fade and resistance rise compared to using silicon or tin alone. The tin layer next to the solid electrolyte prevents volume expansion of the silicon layer during charging, which improves cycling stability. The silicon layer between tin layers further reduces expansion. This layered anode structure enables higher capacity silicon utilization compared to composites.

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