Dendrite Prevention in EV Batteries

Three-dimensional lithium anode for high-capacity lithium-ion batteries that addresses the limitations of graphite anodes. The anode has a vertical structure with columnar or grid-shaped lithium deposited on a copper substrate. A conformal capping layer is deposited over the lithium to protect it and prevent dendrite growth. The vertical structure allows higher lithium loading density compared to flat graphite anodes. The capping layer prevents volume expansion and ensures stable cycling. The 3D lithium anode has higher capacity, lower weight, and better cycling compared to graphite anodes.

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Negative electrode for lithium metal batteries with improved cycle life and reduced volumetric change during charging. The negative electrode has a protective layer on the lithium metal surface with particles sizes between 1-100 microns. The protective layer has a Young's modulus of 106 Pa or greater. This provides mechanical strength to prevent dendrite growth and volumetric expansion during charging. The protective layer also improves lithium deposition density compared to bare lithium metal electrodes.

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An all solid state battery design to prevent short circuits in the anode during charging by controlling the resistance distribution. The battery has a coating layer with lithium titanate on the anode current collector. The coating exists in the region where the anode and cathode are opposing but is omitted in the region where they are not opposed. This helps balance charge reaction progression in both regions. In the opposed region, the coating provides a conductive path to lower anode potential. In the non-opposed region, the coating omission reduces resistance compared to the coated region. This prevents uneven charge reaction progression and minimizes short circuits in the anode.

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Lithium electrode for batteries with a protective layer to prevent dendrite growth in lithium metal anodes. The protective layer is a composite of two layers: a first layer close to the lithium metal with high ion conductivity, and a second layer further from the lithium metal with high electrical conductivity and mechanical strength. The first layer allows lithium ions to pass and prevents lithium depletion. The second layer transfers electrons to the lithium surface and prevents localized current density. The composite layer structure inhibits dendrite growth and improves battery performance compared to single-layer coatings.

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Lithium battery with high energy density and improved cycle life by using a lithium-silicon composite negative electrode. The battery has a lithium-silicon composite negative electrode active material with elemental lithium and a lithium-silicon alloy. The battery also has a protective layer on the negative electrode to suppress side reactions and lithium plating. During charging, the battery is stopped at a lower cutoff voltage where no lithium is deposited on the negative electrode. This prevents dendrite formation and improves cycle life.

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Low cost, reinforced solid polymer electrolytes for lithium-ion batteries that provide improved mechanical, electrochemical, and thermal stability compared to existing solid electrolytes. The electrolyte is made by coating a porous substrate with a fluoropolymer-ionic liquid-lithium salt solution on one side and a fluoropolymer-LLZO solution on the other side. The coated substrate is then dried and cured to form the solid electrolyte. The reinforced electrolyte has better ionic conductivity, lower dendrite growth, and higher thermal stability than pure solid polymer electrolytes.

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Lithium-ion battery with improved cycling life, energy density, and safety by mixing single crystal and polycrystal positive electrode materials in separate cells. The battery has a bare cell cavity with separate cells containing either a single crystal low-nickel positive electrode or a polycrystal high-nickel positive electrode. This allows leveraging the shrinkage property of polycrystal high-nickel materials at high charge levels to reduce stress on the negative electrode and prevent lithium plating. The single crystal low-nickel materials mitigate issues of gas production, safety, and storage degradation at high charge levels.

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Composite electrolytes for lithium-ion batteries with improved stability against dendrite growth and resistance to cracking when used with high-capacity lithium metal anodes. The composite electrolytes have a high volume fraction of inorganic solid electrolyte embedded in an organic polymer matrix. The inorganic component provides ionic conductivity while the polymer prevents dendrite growth and cracks. The composite electrolytes have fracture strengths between 5-250 MPa. The inorganic material can be a lithium-stuffed garnet oxide or antiperovskite oxide. The organic polymer can be entangled with a surface species on the inorganic particles. The composite electrolytes prevent dendrite formation and cycling at high current densities without cracking compared to pure organic electrolytes.

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Coatings for battery separators and other porous substrates that improve safety and performance. The coatings contain a polymeric binder, heat-resistant particles, and optional components like cross-linkers, shutdown agents, adhesion agents, friction-reducing agents, and thickeners. The coatings provide better heat resistance, dendrite blocking, compression resistance, adhesion, friction reduction, and shutdown performance compared to uncoated separators. The coatings can be applied to battery separators to improve safety and performance, particularly during abuse conditions like overcharge and overdischarge.

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Battery pack design that maintains optimal pressure inside the battery cells to improve lifespan and performance. The battery pack has a housing with movable rigid plates and compression springs that axially compress the battery chamber when closed. This pressurizes the cells. When pressure rises, the plates expand the chamber to prevent rupture. The springs are shape memory alloys that bias the plates closed. This allows automated pressure control for lithium metal batteries to prevent dendrite growth.

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Lithium battery separator that combines the benefits of polymer separators and solid ceramic electrolytes for improved battery performance. The separator is a three-layer structure with ceramic electrolyte coatings on either side of a polymer separator. The ceramic layers, made of materials like lithium aluminum germanium phosphate (LAGP), provide high ionic conductivity, stability, and prevent dendrite formation. The polymer separator provides flexibility and mechanical strength. The hybrid separator shows better electrolyte uptake, ionic conductivity, interface stability, cycle life, and voltage polarization compared to regular polymer separators.

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Lithium metal composite electrode material for lithium metal batteries with improved cycle stability and reduced dendrite formation compared to conventional lithium metal electrodes. The composite electrode material has a lithium-containing conductive layer grown in situ on the surfaces of lithium metal particles. This layer isolates the lithium metal from the electrolyte to reduce irreversible reactions and dendrite growth. The layer includes an inorganic lithium compound and lithium alloy. The layer serves as a 3D framework structure that coats the lithium metal particles. This framework reduces volume expansion and dendrite formation during cycling. The composite electrode material is prepared by mixing lithium metal, a metal compound, and conductive carbon, then heat treating to grow the in situ layer.

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Charging method and battery management system for electric vehicle batteries that balances charging speed and safety. The method involves determining a negative electrode potential safety threshold based on factors like state of charge, temperature, and health. During charging, the request current is adjusted based on the negative electrode potential and safety threshold to improve speed while preventing lithium plating.

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Lithium-ion battery with improved energy density, cycle life, and safety by optimizing the negative electrode structure. The battery has a laminated composite negative electrode with a sequence of lithiophilic, main body, and lithiophobic layers on the current collector. This sequence reduces dendrite growth and improves cycle life. The ratio of negative to positive capacity is kept less than 1 to boost overall energy density.

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A system to mitigate degradation of secondary batteries used in devices like electric vehicles and energy storage systems. The system monitors battery usage and identifies factors contributing to battery degradation. Based on the degradation factors, it optimizes battery charging and discharging to suppress battery degradation. This involves techniques like temperature management, current limits, and capacity balancing to prevent issues like capacity loss, cracking, and lithium plating. By tailoring battery operation to the specific degradation mechanisms, it aims to extend battery life compared to generic charge/discharge profiles.

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A nonaqueous secondary battery with a stacked separator structure that provides improved performance and reliability compared to using a single separator material. The battery has separators with different pore sizes between the electrodes. This allows optimizing ionic conductivity and electrode insulation properties separately. The stacked separators prevent direct electrode contact, reduce whisker growth, and block deposit buildup. The separator stack also resists shape change in flexible batteries.

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Battery cell force management system to optimize performance of rechargeable battery packs, like solid-state pouch cells, by maintaining proper pressure on the cells during charging, discharging, and idle states. The system uses movable end plates that apply force to the cells. Sensors measure force changes during charge/discharge and a drive mechanism adjusts plate position to compensate. This prevents capacity fade, uneven expansion, dendrite growth, etc. by keeping consistent cell stack pressure.

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A lithium metal negative electrode for lithium-ion batteries that addresses the issues of dendrite formation and interface side reactions. The electrode has a porous carbon layer with pores formed by desorbing adsorbed gas during slurry coating. This creates a 3D pore structure in the carbon layer that prevents dendrite growth and reduces side reactions compared to a smooth carbon layer. The pore structure allows lithium metal to deposit inside the pores instead of on the surface, reducing dendrite formation. The pores also provide a pathway for lithium ion transfer, mitigating side reactions.

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Monolithic ceramic electrochemical cell for solid-state lithium-ion batteries with integrated electrodes and separator. The cell has a ceramic housing with interconnected electrode spaces. The electrodes have 3D porous structures with conducting networks on sidewalls. The separator is solid ceramic. During charging, lithium forms in the anode space and ions move through the ceramic separator. This eliminates the need for liquid electrolyte and prevents dendrite growth. The 3D porous electrodes improve performance by enhancing lithium ion and electron access. The monolithic design allows hermetic sealing of the anode.

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Secondary battery with improved charge-discharge efficiency and cycle life in aqueous electrolyte batteries. The battery has composite layers on the negative and positive electrodes that contain inorganic particles and a polymer. The composite layers are joined to the electrodes but have a low peel strength between them. This allows gas generated during charge/discharge to escape outside the battery rather than accumulating inside. This prevents internal short circuits and degradation. The composite layers also have high densities to suppress electrolyte penetration and dendrite growth.

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Sandwich composite separator for lithium-ion batteries that improves battery life and performance by preventing anode degradation during cycling. The separator has an anode protection layer between two base films. This sandwich structure prevents the anode protection layer from peeling off during use, enabling stable anode protection over time. The anode protection layer captures transition metals and blocks lithium dendrite growth to reduce anode degradation.

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Secondary battery with improved cycle life and energy density for applications like electric vehicles. The battery uses a specific type of lithium cobalt oxide positive electrode material that contains projections with elements like Hf, V, Nb, Zr, Ce, and Sm. These projections help stabilize the lithium cobalt oxide structure during charging and discharging to prevent capacity fade and cracking. The projections can also contain additives like Mg, F, and Ni. The method involves mixing lithium cobalt oxide with metal alkoxides containing these elements and heating to form the projections.

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Lithium metal battery negative electrode with a polymer protective film to prevent dendrite growth and improve cycle life. The film is made of a citric acid copolymer with a molecular weight of 10,000 to 1,000,000. The film is applied to the surface of the lithium metal away from the current collector. The copolymer forms a strong and uniform SEI layer on the lithium metal that covers it completely and prevents dendrite formation during cycling.

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Composite lithium metal anodes for lithium-ion batteries that mitigate the problems of excessive dendrite growth, infinite dimensional change, and low power density in lithium metal anodes. The composite anodes have a porous matrix that provides a stable, immobilized framework for the lithium metal. This prevents significant expansion and contraction during cycling compared to bare lithium foil. The matrix also has high surface area to facilitate uniform, dendrite-free lithium deposition. The composite anodes have improved cycling stability, dendrite suppression, and low overpotential compared to bare lithium foil.

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Charging lithium metal batteries with ultrasonic vibration to prevent dendrite formation and improve charging efficiency. The method involves applying ultrasonic vibrations to the lithium metal negative electrode during charging. This softens the metal and reduces inhomogeneities that can cause dendrites. It also redistributes lithium ions to improve contact with the electrolyte and current collector.

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Detecting lithium dendrite formation in Li-ion batteries to prevent short circuiting and cell failure. A porous conductive layer is sandwiched between the anode and cathode. As a dendrite grows towards the cathode, it contacts the conductive layer before the cathode. This reduces the voltage between the anode and layer, indicating dendrite presence. Sensors monitor this potential change to diagnose dendrite formation. If detected, the cell can be isolated to prevent dendrite growth through the layer and contacting the cathode.

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Batteries with improved safety, cycling stability, and energy density by using lithiated carbon-coated lithium metal anodes, sulfurized carbon cathodes, and graphene nanoribbon (GNR) modified separators. The lithiated carbon coating on lithium metal prevents dendrite formation during charging, the sulfurized carbon cathodes have high capacity and reduced polysulfide shuttle, and the GNR-modified separators prevent sulfur migration.

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High energy density, transportable liquid metal batteries with improved performance and safety. The batteries have features like using liquid metal electrodes, operating temperatures above 250°C, and pressurized containment to enable high energy density. The batteries can charge/discharge rapidly, have long cycle life, and can be shipped as solid metal then activated on site to form the liquid cells. This allows transporting the batteries on vehicles with high power density while avoiding solid electrode issues like dendrite formation.

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All-solid-state battery design with improved durability by preventing non-uniform lithium deposition and dendrite growth. The battery has a planar shape with a specific area-to-perimeter ratio of 0.7 or less. This prevents lithium from concentrating at the edges due to higher surface energy, which can cause short circuits and dead lithium. By reducing the perimeter relative to the area, lithium ions are less inclined to migrate to the edges and deposit uniformly.

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A metal accumulation inhibiting supplement for rechargeable batteries to reduce metal deposition on electrodes and improve battery performance. The supplement is added to battery components like electrolytes, separators, and electrodes to prevent metal accumulation on electrodes during charging. The supplement contains synthetic compounds similar to natural lipids found in rubber trees that migrate into the electrolyte and attract to metal surfaces. This forms a barrier on the electrodes that reduces metal plating and gas evolution. The supplement foams in the electrolyte as a visual indicator of activity.

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Vehicular battery control device to prevent lithium metal precipitation in low-temperature lithium-ion batteries by proactively reducing charge capacity before a predicted low-temperature charge event. The device checks battery temperature and charge state to determine if lithium metal precipitation is possible. If so, it lowers charge capacity until it's below the precipitation threshold before a predicted low-temp charge event. This prevents lithium metal formation when charging at low temperatures.

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Negative electrode plate design for high energy density lithium-ion batteries with long cycle life, high rate charging, and reduced safety risks. The design balances gram capacity and thickness of the negative active substance layers. The first layer has high capacity active material for higher areal capacity. The second layer has lower capacity material for easier ion transport and reduced dendrite formation. The ratio of gram capacity in the first layer to total thickness (A/B) and the ratio of gram capacity in the second layer to thickness (C/D) are optimized ranges.

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Smart Battery Management System (SBMS) that predicts and prevents battery failures like thermal runaway in cells using sensors, machine learning, and active control. The SBMS monitors metrics like pressure, temperature, voltage, etc. from cells and predicts failure events using a trained neural network. It then proactively disconnects cells with high failure risk to prevent catastrophic failures. The SBMS also load balances cells to prevent dendrite growth and thermal runaway.

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Operating lithium metal and anode-free cells in a repeatable manner to achieve cycle life and energy density requirements. The method involves connecting the cells in series in modules and controlling charging/discharging using bi-directional DC-DC converters. This allows independent cell measurement and repeatable stopping at defined SOC limits. By leaving some charge in anode-free cells to prevent dendrite growth, it enables practical use. This reduces gas generation, swelling, and failure compared to fully depleting.

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Testing batteries during manufacturing by measuring electromagnetic signatures using an antenna inside a test fixture. The antenna detects the EM signature as the battery cycles between charge and discharge. This allows characterizing the battery internally before assembly to identify defects like dendrite formation. The EMIS module analyzes the signals to detect battery cell characteristics.

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A metal accumulation inhibiting supplement for rechargeable batteries to prevent issues like dendrite growth, electrode erosion, and short circuiting. The supplement is added to the electrolyte and foams when agitated, indicating an effective concentration. The supplement is a synthetic version of compounds found in natural rubber, like phospholipids and glycolipids, that migrate from the separator material into the electrolyte. These lipids accumulate on the negative electrode surfaces to inhibit metal accumulation and foaming during charging. The supplement provides a visual indicator of activity by foaming the electrolyte.

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Smart rechargeable energy storage device like electric vehicle batteries with improved performance, safety, and sustainability using pure organic carbon-based graphene. The device uses graphene as the active material in the electrodes and electrolyte instead of traditional materials like lead, graphite, and liquid electrolytes. This provides higher energy density, faster charging, eliminates safety hazards, and enables solid-state batteries. The graphene-based electrodes improve ion transport and eliminate dendrite formation. The graphene electrolyte prevents short-circuiting and improves stability. The device also has smart thermal management and heat sensors for safe operation.

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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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Polymer gel electrolyte for lithium metal batteries that improves oxidation stability, reduces dendrite formation, and prevents lithium plating. The electrolyte contains a lithium salt, ether-based solvent, nitrate, and a cross-linking agent. The nitrate forms a stable film on the electrode surface and the ether solvent improves compatibility with lithium metal. The cross-linking agent creates a gel electrolyte. A protective layer between the anode and separator contains nanofibers with oxide particles having double bonds. This provides a stable interface and suppresses dendrites.

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A separator for aqueous electrolyte batteries like aqueous lithium-ion batteries that provides both high density to prevent electrode dendrite penetration and good electrolyte retention. The separator has a composite membrane with two layers, one dense and one less dense, sandwiched between substrate layers. The less dense layer has lower void content compared to the substrate layer to balance density and electrolyte retention. This prevents electrolyte leakage while still allowing some impregnation. The dense layer prevents dendrite penetration. The composite separator has very low air permeability for good sealing.

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All-solid-state battery with uniform lithium deposition and improved durability by balancing the binding forces at the interfaces between the functional layer, solid electrolyte, and anode current collector. The binding force ratio between the second interface (functional layer-anode) and first interface (functional layer-solid electrolyte) is 0.6 or higher to prevent lithium concentration gradients and uneven deposition. The uniform lithium deposition helps avoid dendrite growth and improves battery life.

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An all-solid-state battery design that improves the performance of anodeless-type all-solid-state batteries. The battery has a composite cathode, electrolyte layer, and anode current collector. The electrolyte layer contains recesses that are depressed into one surface. These recesses provide spaces for lithium to reversibly precipitate during charging. This prevents uneven lithium growth and isolation. The recesses also prevent lithium from forming dendrites and moss, and provide uniform pressure for lithium dissociation. The recesses improve lithium utilization and battery performance in anodeless-type all-solid-state batteries.

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Secondary battery with improved cycle life, rate performance, and safety compared to conventional batteries. The battery has a unique structure in the positive electrode where graphene layers sandwich and surround the active material particles. This forms an electron conductive network to improve electron transfer in the active material layer. It also provides mechanical support and bonding between the particles. The graphene layers wrap the particles and overlap to prevent cracking and breakage. The graphene can be dispersed graphene oxide with specific oxygen content. This allows stable graphene dispersion and formation in the electrode. The battery also uses a titanium-coated current collector to prevent dendrite growth during charging.

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Monolithic ceramic electrochemical cell housing for high energy density lithium-ion batteries that eliminates the need for liquid electrolyte and allows solid-state batteries to be manufactured at lower cost and higher energy density than existing solid-state batteries. The housing is made by depositing precursors in layers and sintering them into a single monolithic structure. The housing has multiple subcells with ceramic separators, anodes, and cathodes. The anodes are 3D porous structures with ionic conduction through strands, pores, and networks. This allows lithium to form in the pores during charging, avoiding dendrite growth and short circuits.

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A separator for lithium metal batteries that prevents internal short circuits caused by lithium dendrite growth. The separator has three layers: a lower layer, an intermediate layer with lithiophilic materials like phosphorus-doped graphitic carbon nitride, and an upper layer. The lithiophilic intermediate layer inhibits lithium plating and dendrite growth on the separator surface, preventing short circuits between the lithium metal negative electrode and other battery components.

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Improved anode materials for lithium-ion batteries with high capacity, stability, and cycle life. The anode structure involves agglomerated nanocomposites made of dendritic nanoparticle cores with discrete nanoparticles of silicon or other Group 4A elements attached. This creates a porous composite anode with interconnected nanocomposites. The dendritic cores provide mechanical stability while the discrete nanoparticles accommodate volume expansion during charging. The interconnected structure allows lithium ion transport between the nanocomposites. This improves stability and capacity compared to dispersed silicon nanoparticles.

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Electrode assembly, battery cell, battery, and electric device design to reduce lithium plating and improve safety in lithium-ion batteries. The electrode assembly has a barrier between adjacent bent sections of the positive and negative electrodes in the winding. This blocks ions from the first bent section deintercalating into the second bent section, preventing lithium plating when the negative electrode sheds. The barrier also supports the bent sections to reduce vibration and shedding. The barrier extends beyond the bent sections in a perpendicular direction. This reduces vibration amplitude, impact force, and shedding, further preventing lithium plating.

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Lithium-ion batteries with improved cycle life and reduced anode degradation for applications like electric vehicles. The batteries contain a lithium anode, cathode, electrolyte, and separator with added nitrogen-containing compounds. The compounds form a uniform ion-conductive layer on the lithium anode during cycling, preventing dendrite growth and high surface area lithium. This improves anode morphology and reduces anode consumption compared to conventional lithium-ion batteries.

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A lithium-ion battery design with monolithic ceramic electrochemical cell housing to enable high energy density and avoid dendrite formation. The housing has multiple subcells with integrated anode and cathode compartments separated by ceramic electrolyte. The anode is a 3D porous structure with ionically conducting strands, pores, and a coated network. During charging, lithium forms in the pores. This eliminates dendrites and allows full utilization of lithium anode capacity. The ceramic electrolyte maintains conductivity throughout the cell. The monolithic design also enables hermetic sealing of the anode space.

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Inorganic particles for nonaqueous electrolyte batteries that improve safety and life characteristics by adsorbing metal ions in the battery. The particles contain a cation exchanger with a highly crystallized one-dimensional tunnel-like crystal structure. This structure allows the particles to effectively adsorb metal ions present or generated in the battery. The particles can be added to battery components like electrodes, separators, and electrolytes to prevent metal deposition, short circuits, and capacity loss. The tunnel-like crystal structure enables high ion adsorption capacity.

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