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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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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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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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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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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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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Lithium secondary battery with high energy density and improved cycle life by balancing efficiency between the positive and negative electrodes. The battery uses specific compositions and additive levels in the electrode materials and electrolyte. The positive electrode contains a lithium composite transition metal compound like nickel-cobalt oxide. The negative electrode has a mixed active material of silicon and carbon. The electrolyte contains fluoroethylene carbonate. When the efficiency constants of the positive and negative electrodes and the electrolyte additive meet a specific equation, it improves energy density and cycle life compared to unbalanced efficiency.

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Solid electrolyte for lithium-ion batteries with high ionic conductivity for improved battery performance. The electrolyte is a lithium phosphorus oxysulfide (LPSO) compound represented by the formula Li3PSxOy, where x is between 3.7 and 3.8 and y is between 0.2 and 0.3. The LPSO is manufactured by annealing a precursor made of lithium, phosphorus, sulfur, and oxygen at temperatures between 240-300°C for durations between 1-4 hours. This process forms the LPSO with a unique crystal structure that provides unexpectedly high ionic conductivity.

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Solid electrolyte for solid-state lithium-ion batteries that can function effectively in solid-state batteries and improve safety, thermal stability, energy density, power density, and broad temperature range compared to conventional liquid electrolytes. The disclosed solid electrolyte is a compound NaxLi3-xYCl6 with 0<x<3, where it can have a trigonal ordered crystal structure. This compound exhibits high lithium and sodium ion conductivity, making it suitable for lithium-ion, sodium-ion, or dual-ion batteries. The solid electrolyte is placed between the battery electrodes during manufacturing.

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Solid electrolyte for high-performance batteries and capacitors with improved stability and reliability. The electrolyte contains lithium, praseodymium, zirconium, oxygen, and one or more of sulfur, bismuth, arsenic, germanium, or tellurium. The electrolyte has a garnet-type crystal structure with a composition that allows lower sintering temperatures compared to conventional garnet-type electrolytes. The lower sintering temperatures prevent evaporation of lithium and other components during sintering, improving atmospheric stability. The electrolyte also has higher density and less segregation of impurity phases compared to conventional garnet-type electrolytes.

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Secondary lithium-ion battery with improved initial DC resistance and cycle performance at high temperatures by reducing water absorption and internal resistance. The battery uses a positive electrode with optimized porosity, achieved by adding a pore-forming agent in the slurry. The electrolyte contains a specific amount of a dehydrating additive, based on the total electrolyte mass. This helps balance the increased porosity to prevent water absorption while reducing unwanted water generation during charging. The battery meets conditions like 0.4 ≤ (a/P) ≤ 3.3 to balance energy density, DCR, and cycle life.

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Secondary battery with improved performance for lithium metal anodes using a protective layer and electrolyte composition. The battery has a negative electrode with an alkali metal, like lithium, covered by a fluoroelastomer protective layer. The electrolyte contains fluorinated and non-fluorinated ether compounds. This setup reduces side reactions between the lithium and electrolyte, mitigating dendrite growth and improving cycle life. The fluorinated ether compounds provide improved ionic conductivity and safety compared to traditional ether electrolytes. The non-fluorinated ether compounds help optimize solvent properties. The protective layer further reduces contact between lithium and electrolyte to minimize side reactions.

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A method for improving the initial and cycle life of lithium-ion batteries with silicon anodes. It involves pre-lithiating the batteries using an auxiliary lithium electrode connected to the cell terminals. This allows controlled diffusion of lithium ions from the auxiliary electrode into the anode during formation to mitigate capacity loss from side reactions. It also provides additional lithium reserve at the anode beyond the cathode capacity for cycling. This reduces capacity fade between cycles. The auxiliary electrode voltage is adjusted to keep the cell voltage near zero during lithium transfer.

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A secondary battery with improved reliability by preventing internal short circuits and swelling-induced package failure. The battery has a unique positive electrode design with a thicker region adjacent to a thinner region. This helps prevent separator displacement and short circuits between the positive and negative electrodes during cycling. It also reduces stress concentrations in the outer package due to negative electrode swelling. The thicker region provides a mechanical anchor for the separator while the thinner region allows expansion without separator movement.

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Battery cell design for lithium-ion batteries to reduce lithium plating and improve performance, especially at cell corners. The cell has curved surfaces on the negative and positive electrode plates that meet certain capacity ratio requirements. At the corners, the ratio of surface capacities between the adjacent negative and positive curved surfaces is greater than or equal to 1. This prevents lithium precipitation by balancing lithium insertion on both sides.

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Electric vehicle power and control system with improved charging efficiency and power capacity. The system has an electronic control unit with dual CAN bus interfaces, a touch screen monitor, and customizable software. The battery management system has a base unit connecting stack units for balancing and monitoring cells. The power control and distribution box has bus bars for fuses, contactors, pre-charger, isolation, and current monitors. The battery housing system integrates cells with the stack units. This allows customization and replacement of components while leveraging off-the-shelf parts.

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