Magnesium-Ion Batteries Development for Electric Vehicles

Electrode assembly design for batteries that reduces misalignment of electrode sheets and prevents lithium plating. The electrode assembly has folded electrode sheets with alternating laminated parts. Each folded part has a guide section that helps the folding process. The guides can be grooves or holes. This prevents sheet shifting during assembly. The folded structure allows the negative sheet to extend beyond the positive sheet edge, preventing lithium plating issues.

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Power supply device with integrated temperature sensing to improve internal structure and energy density. The power supply includes at least one battery pack, and a temperature sensing module that attaches directly to the battery pack. The module has a bracket to fix it to the pack, and a temperature sensor that connects thermally to the pack. This allows internal temperature monitoring without taking up external space. The integrated bracket prevents loose structure inside the power supply.

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Protective coating for magnesium anodes in batteries to enable stable cycling and improve capacity. The coating is a layer of silylated cellulose, which is cellulose treated with silicon compounds. The coating is applied to the magnesium anode surface and contains solvated ion-conducting additives. The solvent solvates the additives and also acts as an electrolyte. The silylated cellulose coating with embedded solvated additives provides a protective barrier for the magnesium anode that allows ionic conduction.

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Electrode assembly for batteries that reduces cracking of the electrode plates during winding and stacking. The assembly has anode and cathode sheets with active material coatings. The cathode sheet has an additional non-active material layer connected to its edge. This layer extends beyond the anode active material projection on a perpendicular plane. It prevents shear stress on the anode layer caused by the cathode edge. The additional layer shields the anode from sharp cathode edges. This prevents cracking and delamination of the anode during winding and stacking.

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Nanoconfined metal-containing electrolyte for batteries that mitigates metal dendrite growth and combating electrolyte leakage issues. The nanoconfined electrolyte contains a layer of enclosed hollow nanostructures filled with a liquid metal-containing electrolyte. The enclosed nanostructures physically contact each other to provide conductivity. The nanoconfinement prevents dendrite growth while retaining the high conductivity of liquid electrolytes. The nanoconfinement is achieved by forming a layer of hollow nanostructures and infusing them with liquid electrolyte.

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Sodium-magnesium hybrid battery with a layered oxide cathode material to overcome the issues of capacity loss and poor diffusion kinetics in sodium and magnesium batteries. The battery uses a layered oxide cathode made of a P2 phase material containing sodium, manganese, and oxygen. The cathode is combined with a magnesium or magnesium alloy anode instead of the typical graphite anode. This allows sodium and magnesium intercalation into the cathode for reversible cycling, avoiding capacity loss issues seen in sodium-only batteries. The magnesium anode also improves diffusion compared to conventional magnesium batteries due to the weaker Mg-O bond in the layered oxide cathode.

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A method for producing high-performance electrode materials for rechargeable batteries like lithium-ion batteries that can rapidly charge and discharge without degradation. The method involves flash calcining precursor powders in a gaseous medium using an externally heated flash calciner reactor. This produces nano-active powder materials with desirable properties for battery electrodes like high porosity, high pore surface area, high flexibility, and high strength. The flash calcining process allows rapid intercalation of ions into the electrodes for fast charging and discharging without degradation.

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Battery cell design to improve safety by preventing internal short circuits. The design involves reinforcing the guide segment between the battery tab and electrode stack to prevent deformation during bending. The reinforcement extends from one end to the other matching the size of the guide segment in the bending direction. This reduces bending stress on the electrode stack when the tab bends, preventing it from compressing and delaminating the electrode layers.

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Non-aqueous electrolyte electrical storage devices like lithium-ion batteries with improved safety by trapping hydrogen sulfide gas generated inside the battery during operation. The battery has an electrode composition that can intercalate lithium ions like regular lithium-ion battery electrodes. However, instead of using a transition metal oxide or other high voltage oxide for the positive electrode, it uses sulfur which has lower voltage but much higher theoretical capacity. When the battery is charged, lithium ions intercalate into the sulfur electrode. This prevents hydrogen sulfide gas from being generated during charging like it can with oxide electrodes. The sulfur electrode also has lower risk of thermal runaway and oxygen release compared to oxides.

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Battery design with internal output terminal that improves energy density compared to external terminals. The battery has a mounting seat integrated into the cell stack. The output terminal is connected internally to the cells and then fixed to the seat. This eliminates the need for an external terminal seat and reduces internal volume compared to conventional designs with external terminals. The internal terminal also reduces torsion forces on the cell stack compared to external terminals bolted to an external seat. The battery can be manufactured by connecting the cells, adding the internal terminal seat, and then fixing the terminal to the seat.

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Battery cell design and manufacturing method to improve reliability and safety by exposing the welded joint between the current collector and electrode terminal. In the cell assembly process, instead of fully covering the welded joint with electrode material, a portion of the joint is left exposed. This allows visual inspection of the welded joint to ensure it is properly made and prevents hidden defects. It also facilitates better cooling of the joint area and potential for additional monitoring sensors to be added.

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Positive electrode material for high-capacity non-water magnesium batteries that enables faster diffusion of magnesium ions, high reversible capacity, and high reaction potential. The positive electrode contains layered nickel oxyhydroxide (NiOOH) as the active material. This layered structure allows occlusion and release of magnesium ions between the layers. It addresses the slow diffusion of multivalent ions like magnesium in positive electrodes. The layered nickel oxyhydroxide enables better magnesium ion mobility compared to other forms of nickel oxyhydroxide, enabling high-capacity magnesium batteries.

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Lithium-ion battery design with higher energy density, smaller size, lighter weight, and lower cost compared to conventional batteries. The design uses a self-supporting sheet of lithium cobaltite (LCO) electrode material that is sintered together. This sheet serves as a mechanical support for a continuous solid electrolyte layer made of lithium phosphorous sulfide (LPS). The LPS infuses into the porous channels of the LCO sheet during manufacturing at high temperatures. This allows a binder-free, high concentration solid electrolyte without needing a separate substrate.

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Battery module design to improve safety and energy density of secondary batteries like lithium-ion. The design involves using mixed chemistries of battery cells in the module, with optimized cell density ratios to balance safety and energy density. The cells are arranged in parallel with spacing to enable heat transfer between cells of different chemistries. By controlling the density ratio of high vs low expansion cells, it balances safety and energy density. This allows higher energy density modules with better thermal management compared to using all high expansion cells.

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Batteries with nanoprocessed coatings on cathode, anode, and solid electrolyte materials to improve battery performance and cycle life by blocking unwanted side reactions and preventing capacity fade, voltage fade, and resistance increase. The coatings are thin, continuous, conformal, ionic conductive, and mechanically stable. They can be deposited using techniques like atomic layer deposition or molecular layer deposition. The coated materials are used in solid-state or liquid-electrolyte batteries. The coatings encapsulate the active materials, barrier the electrolyte, or modify the electrode surface chemistry. The nanoprocessed coatings address issues like SEI growth, phase transformations, electrolyte depletion, ionic shuttling, and electrode dissolution.

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Magnesium sulfide material, magnesium sulfide composite material, positive electrode for secondary batteries, magnesium secondary batteries, and wide band gap semiconductor materials with improved characteristics for applications like batteries, electronics, and sensors. The materials have magnesium sulfide with a zinc blende crystal structure. This structure forms during discharge of magnesium sulfide in batteries, or by heating sulfur and magnesium. It has better ionic conductivity, charge capacity, and stability compared to other magnesium sulfide forms. The materials can be produced by discharging magnesium sulfide in an electrolyte containing magnesium salt.

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A multi-element lithium-magnesium alloy anode material for lithium-ion batteries that prevents pulverization, inhibits dendrite growth, and provides long cycle stability. The anode contains a lithium-magnesium solid solution matrix and a Li-M intermetallic compound. It also provides a modified electrolyte that is compatible with the alloy anode and significantly improves cycle stability when used together. The electrolyte contains an ester solvent, lithium salt, organic additive, and inorganic additive.

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Magnesium ion hybrid supercapacitor with improved energy density compared to traditional lithium-ion batteries. The supercapacitor uses magnesium-based materials for reversible deposition/dissolution of magnesium ions. The cathode contains magnesium-based composites like graphene/Mg, carbon fiber/Mg, or CNT/Mg. The electrolyte uses magnesium salts like Mg(TFSI)2 or Mg(CF3SO3)2. This allows magnesium ion storage instead of lithium, addressing the issue of lithium resource constraints. The magnesium-based materials in the cathode provide reversible deposition/dissolution of magnesium ions, improving energy density compared to lithium-ion batteries.

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Converting diesel-electric or diesel locomotives to all-electric, emission-free locomotives for operation on partially electrified rail lines. The conversion involves adding an electric power storage and supply system to the locomotive. The system uses a combination of accumulators and super capacitors to provide autonomous power when external electrical infrastructure is not available. The locomotive can operate in external power mode when connected to the grid, but also in autonomous mode when disconnected. This allows it to operate on partially electrified lines without external power. The locomotive can switch between modes seamlessly.

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Integrated energy storage system using a hybrid design of thin and thick cathode cells to deliver power to applications requiring high pulsed power and low temperature starts. The system includes a combination of high power thin cathode cells for pulse loads and low temperature starts, high energy thick cathode cells for baseline loads, and a controller to allocate power between them based on load and temperature. This allows optimized performance for specific applications while leveraging the benefits of each cell type.

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