63 patents in this list

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Solid-state batteries promise to revolutionize energy storage with their potential for higher energy density and improved safety. However, achieving these benefits requires overcoming significant technical hurdles. Hyundai is deeply engaged in this field, exploring innovative approaches to enhance performance and reliability in solid-state battery technology.

One main challenge is ensuring efficient ion transport while maintaining structural integrity and stability under various conditions. Researchers face obstacles such as dendrite formation, electrolyte stability, and maintaining consistent pressure within the battery cells. Addressing these issues is crucial for developing commercially viable solid-state batteries.

This page delves into Hyundai's research, showcasing strategies like advanced layering techniques, novel electrolyte compositions, and pressure control systems. These approaches aim to enhance ion conductivity, suppress dendrite growth, and ensure stable operation, paving the way for more reliable and efficient solid-state batteries in the future.

1. Manufacturing Method for All-Solid-State Batteries Using Extended Electrode Layering and Folding Technique

HYUNDAI MOTOR CO, KIA CORP, 2024

A manufacturing method for all-solid-state batteries that provides dimensional stability and cell performance without ultra-high pressure pressing. The method involves forming electrode members with extended lengths, layering them, then pressing the stack. This prevents deformation during pressing. After pressing, the extended electrode is folded around the shorter one to create the final battery shape. This avoids the damage and cost increases of ultra-high pressure pressing while maintaining performance.

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2. Lithium Metal Halide-Based Solid Electrolyte with Novel Crystal Structure Identified via Particle Swarm Optimization

HYUNDAI MOTOR CO, INDUSTRY UNIV COOPERATION FOUNDATION HANYANG UNIV ERICA CAMPUS, INDUSTRY-UNIVERSITY COOPERATION FOUNDATION HANYANG UNIVERSITY ERICA CAMPUS, 2024

Lithium metal halide-based solid electrolyte for all-solid-state batteries with improved lithium ion conductivity. The solid electrolyte has a crystal structure different from conventional lithium metal halide-based solid electrolytes. The new crystal structure was discovered using particle swarm optimization (PSO) algorithm to find energetically stable crystal structures. This optimization approach allowed predicting metastable crystal structures that haven't been observed yet but can be synthesized. The resulting new crystal structure provides better lithium ion conductivity compared to conventional lithium metal halide-based solid electrolytes.

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3. All-Solid-State Battery with Elastic Buffer Layer Between Negative Electrode Current Collector and Intermediate Layer

HYUNDAI MOTOR CO, KIA CORP, 2024

An all-solid-state battery design that can suppress volume expansion during charging and discharging. The battery has a buffer layer sandwiched between the negative electrode current collector and the intermediate layer. This elastic buffer helps minimize volume changes in the battery during charge/discharge cycles compared to conventional all-solid-state batteries without the buffer.

4. Coated Sulfide-Based Solid Electrolyte Particles with Metal Alkoxides for All-Solid-State Batteries

HYUNDAI MOTOR CO, KIA CORP, SAMSUNG SDI CO LTD, 2024

Solid electrolyte for all-solid-state batteries with improved performance by coating the sulfide-based solid electrolyte particles. The coating contains metal alkoxides. This coating protects the sulfide electrolyte from defects and reactions during manufacturing and operation. It also reduces interfacial resistance between the electrolyte and electrodes. The coated sulfide electrolyte particles are used in the battery along with the coated electrode materials. The coated electrolyte provides better stability, lower resistance, and improved performance compared to uncoated sulfide electrolytes in all-solid-state batteries.

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5. Sulfide-Based Solid Electrolyte with Lithium, Phosphorus, and Halogen Composition for Enhanced Moisture Stability

HYUNDAI MOTOR CO, KIA CORP, SAMSUNG SDI CO LTD, 2024

Solid electrolyte for all-solid-state batteries with excellent moisture stability and a method to make it. The solid electrolyte is a sulfide-based material with a unique composition containing lithium, phosphorus, and halogen elements like bromine and chlorine. The halogen elements improve moisture stability by preventing water molecules from breaking down the sulfur bonds in the electrolyte. The electrolyte can be made by grinding and heat treating specific compounds containing lithium, phosphorus, halogens, and other elements like tin.

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6. Sulfide-Based Solid Electrolyte Particles with Metal Alkoxide Coating Layer

HYUNDAI MOTOR CO, KIA CORP, SAMSUNG SDI CO LTD, 2024

Solid electrolyte for all-solid-state batteries that improves interfacial resistance and stability in all-solid-state batteries. The solid electrolyte contains sulfide-based solid electrolyte particles with a coating layer on their surface that contains metal alkoxides. This coating layer reduces interfacial resistance between the solid electrolyte and other battery components like the cathode. The coating also improves moisture stability of the sulfide-based electrolyte. The coated electrolyte particles are prepared by dispersing the sulfide particles in a solution of metal alkoxides and solvent, removing the solvent, and drying the particles. This provides a method to manufacture sulfide solid electrolytes with improved performance in all-solid-state batteries.

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7. All-Solid-State Battery with Dual-Layer Sheet for Dendrite Suppression and Lithium Deposition

FOUNDATION OF SOONGSIL UNIV INDUSTRY COOPERATION, FOUNDATION OF SOONGSIL UNIVERSITY-INDUSTRY COOPERATION, HYUNDAI MOTOR CO, 2024

An all-solid-state battery design that prevents lithium dendrite formation and improves energy density. The battery has a three-layer stack with a self-standing sheet layer sandwiched between the positive and negative electrodes. The sheet layer is composed of two distinct layers with different properties. The inner layer promotes lithium deposition while the outer layer suppresses dendrite growth. This prevents dendrites from penetrating the solid electrolyte and shorting the battery. The dual-layer sheet allows efficient lithium storage without dendrite issues.

8. All-Solid-State Battery with Network-Structured Positive Electrode Layer Formed from Treated Carbon Nanotube Film

HYUNDAI MOTOR CO, HYUNDAI MOTOR CO LTD, KIA MOTORS CORP, 2024

All-solid-state battery that can be charged and discharged at room temperature without degradation. The battery uses a unique construction with a network-structured positive electrode layer instead of conventional conductive additives. This layer is made by treating a carbon nanotube film to create interconnected pores. The pores are filled with positive electrode material. This provides conductivity without adding extra powder that can react with the electrolyte or reduce capacity. The battery stack includes the treated positive electrode, solid electrolyte, intermediate layer, negative electrode, and current collectors.

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9. Sulfide-Based Solid Electrolyte with Lithium Oxide Surface Coating and Method of Heat Treatment at Controlled Temperature Range

HYUNDAI MOTOR CO, KIA CORP, SAMSUNG SDI CO LTD, 2024

Solid electrolyte and method for producing the same with uniform particle size distribution, high crystallinity, and ionic conductivity. The method involves mixing sulfide-based solid electrolyte particles with lithium-metal-oxide and heat treating at 250-350°C. This coats the sulfide particles with lithium oxide on the surface, improving the electrolyte properties by providing a uniform particle size distribution, high crystallinity, and enhanced ionic conductivity compared to just the sulfide electrolyte. The heat treatment range allows crystallization without agglomeration issues.

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10. Binder Solution for All-Solid-State Batteries with Ion-Conducting Additive Featuring Complex Lithium Ions and Elevated Boiling Point

Hyundai Motor Company, Kia Motors Corporation, Hanyang University Industry-University Cooperation Foundation, 2024

Binder solution for all-solid-state batteries with improved electrode performance and higher operating temperatures. The binder solution contains a polymer binder, a first solvent, and an ion-conducting additive. The additive is made by dissolving a lithium salt in a second solvent with higher lithium salt solubility. This creates complex lithium ions that increase the electrostatic attraction of the solution. This higher attraction raises the boiling point of the additive compared to the second solvent. When the binder solution is used in the electrode slurry, the higher boiling point additive prevents evaporation during drying. It also forms a smooth ion transmission path in the electrode. The additive composition allows manufacturing all-solid-state batteries that can operate at temperatures of 70°C or higher.

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11. All-Solid-State Battery System with Controlled Pressurizing Fluid Chamber for Consistent Cell Pressure

HYUNDAI MOTOR CO, KIA CORP, 2024

An all-solid-state battery system that maintains consistent pressure on the cells during charging and discharging. The system uses a sealed chamber with pressurizing fluid to surround the stack of solid-state cells. A control unit monitors the battery state and sends signals to adjust the pressurizing fluid level to compensate for cell volume changes during charging/discharging. This allows constant, uniform pressure on the cells regardless of charge/discharge state.

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12. Foldable All-Solid-State Battery with Interleaved Zigzag Electrode and Electrolyte Layers

HYUNDAI MOTOR CO, KIA CORP, 2023

A foldable all-solid-state battery design that avoids short circuits when stacking multiple cells. The battery has folded zigzag layers of anode and cathode electrodes interleaved with electrolyte layers. The folded shape allows the anode protrusions to insert into the cathode recesses and vice versa, preventing short circuits when the cells are stacked. The folded structure is also more compact and enables mass production compared to stacking flat cells.

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13. All-Solid-State Battery with Alloy-Forming Intermediate Layer for Enhanced Lithium Metal Integration

HYUNDAI MOTOR CO, KIA CORP, 2023

All-solid-state battery design with an intermediate layer containing a metal that can form an alloy with lithium to improve energy density. The battery has a negative electrode current collector, an intermediate layer with a metal that forms an alloy with lithium, a solid electrolyte layer, a positive electrode active material layer with the positive electrode active material, and a positive electrode current collector. This intermediate layer composition allows higher lithium metal loading on the anode for improved energy density compared to just using lithium metal on the anode. The metal in the intermediate layer allows better bonding and interfacial stability with the solid electrolyte and lithium metal compared to directly using lithium metal in the anode layer.

14. All-Solid-State Battery with Carbon-Lithium Alloy Intermediate Layer for Uniform Lithium Ion Transport

HYUNDAI MOTOR CO, KIA CORP, 2023

Room temperature all-solid-state battery that can operate normally at room temperature. The battery has a three-layer structure with a negative electrode, an intermediate layer, a solid electrolyte layer, and a positive electrode. The intermediate layer contains carbon and lithium alloy. This allows smooth lithium ion transport at room temperature. The carbon prevents lithium plating on the negative electrode. The lithium alloy forms during charging and provides a seed for lithium deposition. This enables uniform lithium ion precipitation on the negative electrode even at room temperature.

15. Anode-Free All-Solid-State Battery with Intermediate Alloying Metal Layer

HYUNDAI MOTOR CO, KIA MOTORS CORP, 2023

Anode-free all-solid-state battery design that eliminates the need for a separate anode and uses an intermediate layer containing a metal that can alloy with lithium between the current collectors and solid electrolyte. This allows direct deposition of lithium metal onto the anode collector during discharge instead of using a separate anode. The intermediate layer metal acts as a buffer to prevent dendrite growth and improve cycle life. The amount of metal in the intermediate layer can be optimized based on the cathode capacity to balance performance and capacity.

16. All-Solid-State Battery with Lithium Alloy Intermediate Layer and Manufacturing Method

HYUNDAI MOTOR CO, KIA MOTORS CORP, 2023

All-solid-state battery that can operate at room temperature and method for manufacturing it. The battery has a unique intermediate layer between the negative electrode and solid electrolyte. This layer contains a lithium alloy formed from the negative electrode metal during charging. This allows uniform lithium deposition and prevents dendrite growth. The lithium alloy layer enables stable cycling at room temperature without lithiation reactions at high temperatures. The method involves using a precursor layer with a metal that forms an alloy with lithium, which reacts during charging to form the lithium alloy intermediate layer.

17. Cathode Material with Lanthanum-Titanium-Lithium Additive Featuring Vacant Site Crystal Structure for All-Solid-State Batteries

HYUNDAI MOTOR CO, KIA MOTORS CORP, 2023

Cathode material for all-solid-state batteries that improves electron conductivity and enables higher charge/discharge rates. The cathode contains an additive made by calcining a lanthanum, titanium, and lithium precursor. The additive has a unique crystal structure with vacant sites that allows lithium ion migration but prevents electron conduction. This prevents the additive from interfering with the cathode active material's charge/discharge reactions. The additive provides an electron pathway for the cathode during initial cycling when lithium ions are scarce.

18. Cathode with Shear-Stress Applied Solid Electrolyte Coating for All-Solid-State Batteries

HYUNDAI MOTOR CO, KIA MOTORS CORP, 2023

Cathode for all-solid-state batteries that completely coats the cathode active material with a solid electrolyte layer to improve electrochemical performance. The coating layer is formed by applying shear stress to a solid electrolyte powder on the cathode surface. This uniformly covers the active material and provides a seamless interface between the cathode and electrolyte. The coated cathode is mixed with a second solid electrolyte to make the battery electrode.

19. Cathode Active Material with Lithium Transition Metal Oxide Core and xLi3BO3·(1-x)Li2CO3 Coating for All-Solid-State Lithium-Ion Batteries

Hyundai Motor Company, Kia Corporation, Ulsan National Institute of Science and Technology, 2023

Cathode active material and manufacturing method for all-solid-state lithium-ion batteries that improves battery performance and safety. The cathode active material contains a coated core made of a lithium transition metal oxide, with a coating layer consisting of xLi3BO3·(1-x)Li2CO3 (0 <= x <= 1). This composition reduces interface resistance and improves stability compared to traditional cathode materials. The coating is formed by reacting the core with a coating solution during manufacturing.

20. Sulfide Solid Electrolyte with Silicon-Enhanced Ionic Conductivity and Mechanochemical Synthesis

HYUNDAI MOTOR CO, KIA CORP, TOKYO INSTITUTE OF TECHNOLOGY A JAPANESE NATIONAL UNIV CORP, 2023

A sulfide solid electrolyte material with high lithium ion conductivity for all-solid-state lithium ion batteries. The electrolyte contains silicon as a resource-rich component, providing high ionic conductivity. The material is synthesized by mechanically milling an amorphous precursor and then heating it. The resulting sulfide electrolyte can be used in batteries with layers containing the electrolyte for high-performance all-solid-state lithium ion batteries.

21. Cathode with Carbon-Based Conductive Layer and Metal Fluoride Coating for All-Solid-State Batteries

22. Manufacturing Method for Electrodes with Non-Metal Oxide Coated Sulfide-Based Solid Electrolytes

23. Computational Method for Predicting Lithium Ion Conductivity in Solid Electrolytes Using Composition-Based Calculations and Crystallinity Adjustment

24. Iterative Screening Method for Solid Electrolytes Using Crystal Data and Element Substitution

25. Lithium Metal Halide Solid Electrolyte with C2/m Crystal Structure

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