Increase Heat Stability of Solid State EV Batteries

Solid-state thermal battery with actuated heat engines to improve efficiency and reduce thermal shock compared to conventional molten salt batteries. The battery has an insulated container with a stationary thermal storage medium. Actuated heat engines can move in and out of the container to selectively extract heat from the medium. This allows discharging without large thermal gradients that could damage the medium. The engine positions are varied over time to balance heat extraction. This reduces thermal stresses and enables higher power and capacity compared to fixed engine locations.

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Battery design to improve low-temperature performance without adding thermal insulation. The battery has multiple cells where some cells have higher internal resistance and slower heat transfer compared to others. The cells with higher resistance can operate separately at low temperatures to warm up the environment before connecting in series with the other cells. This allows gradual capacity release without severe polarization or lithium plating in the cells with slower heat transfer. The cells with faster heat transfer can have lower resistance.

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Battery pack design with improved low temperature performance for applications like electric vehicles that operate in cold environments. The pack has multiple cells arranged in a temperature gradient inside the pack. The cells are designed with a secondary active material that provides a lower voltage plateau. The cell with the lowest temperature has the highest proportion of the lower voltage plateau capacity. This allows cells in colder regions to discharge further before reaching cutoff voltage compared to cells in warmer regions. This compensates for the lower capacity at low temperatures. The pack's internal temperature distribution is simulated to determine the cell arrangement.

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Process for preparing argyrodite-type solid-state electrolytes for lithium batteries that involves contacting lithium and phosphorus sources with a solvent-reagent at lower temperatures, like 80-120°C, instead of high temperatures like 400-600°C. This allows forming Li7-xPS6-xYx compounds directly in solution, which can then be collected and further processed into solid-state electrolytes. The solvent contains a lithium salt like LiCl and a polymer like PVP. The lower temperature synthesis enables scalable production of argyrodite electrolytes using earth-abundant elements like phosphorus and chlorine.

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A positive electrode, electrode, and secondary battery design to improve cycle life, discharge rate, and low temperature performance of solid-state batteries. The electrode contains positive electrode active material particles, polymer fibers with 1-100 nm diameter, and inorganic solid particles. The polymer fibers help prevent expansion/contraction of the active material during charge/discharge cycles, reducing resistance and cycle degradation. The inorganic solid particles further enhance cycle life and performance by reducing electrode-electrolyte interface resistance. The composite electrolyte layer between the electrodes contains nanofiber dispersed in an aqueous electrolyte solution.

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Process for making high-performance solid-state lithium-ion batteries with improved energy density, cycle life, and safety compared to liquid electrolyte batteries. The process involves mixing ceramic electrolyte powder with flux materials and heating at lower temperatures to form a dense, lithium-conducting electrolyte. This enables depositing thin-film electrolytes with high ionic conductivity suitable for all-solid-state batteries. The lower processing temperatures avoid issues like phase transformation and sintering. The fluxed powder is shaped and heated again at lower temperatures to densify the electrolyte. The lower temperatures and fluxing step allow forming dense electrolytes without sintering issues when directly depositing ceramic powders at high temperatures.

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A secondary battery with improved cycling life and low temperature performance by using a nonaqueous electrolyte containing chlorine ions and a separator with lithium ion conductivity. The battery has a positive electrode with a halide like CuCl2, FeCl3, or CoCl2 as the active material. The negative electrode can have lithium metal, lithium alloys, or compounds that insert/extract lithium. The nonaqueous electrolyte contains an ionic liquid with chlorine anions. The separator allows lithium ion transfer. This combination provides better cycling and low temp performance compared to conventional batteries with aqueous electrolytes.

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An all-solid-state battery system that maintains uniform pressure inside the battery during charging and discharging to prevent cell expansion and contraction issues. The system uses a closed chamber filled with pressurizing fluid to apply isostatic pressure to all cells. A state detector monitors battery conditions. A controller adjusts temperature and fluid flow rates to keep pressure within a range based on cell state. This prevents volume changes from affecting cell pressurization.

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All solid-state battery module with temperature and charge state dependent pressure control to stabilize performance. The battery module has cells sandwiched between pressure plates. A controller adjusts the pressure force based on the battery temperature and state of charge. This allows optimizing internal resistance for charge and discharge efficiency across temperature and charge levels.

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Battery pack for electric vehicles with improved cold weather performance by balancing discharge power in inner and outer areas. The pack uses a mix of battery cells with different chemistries to reduce temperature-related discharge power differences. The inner area has mostly conventional cells, while the outer area has cells with added pseudocapacitance structures. This compensates for temperature-dependent power loss in the outer cells. The inner cells have fewer pseudocapacitance structures since they already have higher temperatures.

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Battery design with a separator and electrolyte composition that provides both high low-temperature cycling and high high-temperature cycling and storage performance. The separator has a double-sided heterogeneous coating with binders having different particle sizes. The anode and cathode surfaces face the smaller particle size coating, while the electrolyte contains a high percentage (10-70%) of a linear carboxylate compound like methyl propionate. This combination enables improved cycling at both extremes compared to conventional designs.

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Carbonate precursor for high-nickel, low-cobalt lithium-ion batteries with improved electrochemical performance. The precursor has a sandwich structure with an inner core and outer shell layer. The inner core has a composition of Ni0.75-0.92Mn0.01-0.15(CO3)x1 and the outer shell has Ni0.70-0.92Mn0.01-0.15(CO3)x2. This sandwich structure allows lithium ions to penetrate through the shell to reach the core during sintering, avoiding cation mixing and local structure collapse in high-nickel materials. The precursor has narrow particle size distribution, good fluidity, and can be prepared in ammonia-free conditions. The sandwich precursor allows complete transformation of high-nickel materials at lower temperatures

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Battery insulation structure that reduces the influence of external temperature on battery performance in both low and high temperature environments. The structure uses a double-walled insulating container with an inner and outer wall. The battery is placed between the walls, spaced away from them. This creates decompression spaces between the walls. This insulation design prevents temperature transfer between the battery and external environment. The decompression spaces also allow the battery to expand/contract without damaging the container walls. Additional features like heat exchange panels, fluid supply/discharge pipes, and concave caps for cable/pipe penetrations further enhance temperature regulation.

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All-solid-state lithium-ion batteries with improved stability and performance using a specific sulfide material as the solid electrolyte. The batteries have a lithium-sulfur-nitrogen (LSN) compound, Li9S3N, as the solid electrolyte. This material provides better stability against electrode materials compared to traditional oxide electrolytes, and has higher conductivity than sulfides like Li2S. The Li9S3N electrolyte is sandwiched between the anode and cathode to form a solid-state battery with improved lifespan and safety compared to liquid electrolyte batteries. The Li9S3N coating on the anode also protects it from reaction with the electrolyte.

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System to prevent lithium plating in battery cells during charging at low temperatures and fast charging by heating the cells directly. It uses carbon nanotube sheets sandwiched between the cells and foam layers. When cell temperature drops below a threshold, a controller sends current through the nanotube sheets to heat the cells. This prevents plating during charging at low temps or fast charging. The nanotube sheets are positioned on the cell faces opposite the cooling plate. The controller can adjust current levels based on temperature ranges.

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Control method to prevent uneven resistance in solid state batteries with layered cathode-anode-electrolyte stack. The method involves actively controlling the temperature distribution across the battery plane to reduce resistance variation between center and edge regions. This mitigates local overcharge/discharge issues caused by pressure differences due to expansion/contraction of the anode. The temperature control is achieved by differentiating center vs edge temperatures to balance resistance. This allows avoiding the need for heavy-duty pressure-uniformizing restraints that increase cost and weight.

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Solid electrolyte for all-solid-state lithium batteries with improved ionic conductivity over a wide temperature range compared to conventional sulfide-based solid electrolytes. The electrolyte contains lithium sulfide, diphosphorus pentasulfide, nickel sulfide, and lithium halide. The composition allows forming a crystalline phase with high ionic conductivity over a wider temperature range compared to conventional sulfide electrolytes.

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Solid catholyte material for solid-state batteries with improved ionic conductivity to allow higher mass loading of active material, faster charge/discharge, and wider temperature range compared to traditional solid electrolytes. The catholyte contains lithium, germanium, phosphorus, sulfur, and oxygen in a specific ratio. The oxygen level is 1:2 or less compared to sulfur to form LGPSO or LSPSO. This composition improves conductivity without adding carbon for electronic conductivity. The catholyte is confined between active material regions in the cathode to prevent reaction. The confinement prevents sulfur loss. A protective material over the catholyte maintains sulfur. The catholyte has a nanocrystalline or amorphous structure.

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Solid battery design with improved characteristics and reliability for applications like electric vehicles, wearables, tools, and electronics. The battery has layers like positive electrode, negative electrode, solid electrolyte, current collector, insulator, and protection. The key innovation is that each layer contains a specific glassy material with a melting point of 500°C or less. The total glassy content in each layer is 10-60 vol%. This balance prevents excessive thermal expansion mismatch during sintering and avoids cracking, warping, or internal shorting. The glassy electrolyte allows room temperature operation.

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A manufacturing process for high-performance, all-solid-state lithium-ion batteries with improved energy density and safety. The process involves depositing thin films of lithium-conducting ceramic electrolytes using a low-temperature, fluxed powder method. The ceramic electrolyte powder is mixed with flux materials at temperatures below 400°C to form a fluxed powder. This fluxed powder is shaped and heated below 1100°C to densify the electrolyte. The low-temperature processing enables thin-film deposition and avoids the high temperatures needed for solid-state reactions. The fluxes aid in densification without melting the ceramic electrolyte. The resulting dense lithium-conducting ceramic electrolyte has improved ionic conductivity for all-solid-state batteries.

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Electrode design for solid-state batteries with reduced resistance at room temperature compared to conventional electrodes. The electrode contains a positive temperature coefficient (PTC) resistor layer sandwiched between the active material and current collector. The PTC layer has an electroconductive material, insulating inorganic substance, and polymer. The key is keeping the roughness of the surface contacting the active material below 1.1 micrometers. This prevents poor contact and followsability of the PTC layer during battery cycling. The low surface roughness allows sufficient contact and followability of the PTC layer with the active material layer while still having a PTC effect during heating.

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Ceramic-containing nanofibers for separators in lithium ion batteries that provide improved thermal stability compared to traditional polymer separators while maintaining sufficient porosity for ion transport. The nanofibers contain ceramic materials like silica or ceramic precursors that form continuous matrices in the fiber. The ceramic content is at least 3-95% by weight, with a core-sheath structure optionally. The nanofibers can have ordered mesopores for flexibility and non-brittleness. The ceramic content and ordered pore structure improve thermal stability compared to polymer separators while maintaining ionic conductivity.

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Sulfide-based solid electrolyte for lithium batteries with high ionic conductivity over a wide temperature range, enabling solid-state batteries with improved safety over conventional liquid electrolytes. The sulfide electrolyte contains lithium sulfide, diphosphorus pentasulfide, nickel sulfide, and lithium halide. The electrolyte forms a cubic crystal structure with high conductivity when heat-treated to crystallize. This wide-temperature conductivity is achieved by optimizing the sulfide and halide composition in the starting material, then milling and heat-treating it to crystallize the optimized phase.

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Battery module with a heat sink containing a phase change material (PCM) capsule to uniformize the temperature of the cooling fluid flowing through the module. The PCM absorbs heat from the battery cells when they generate excess heat, preventing localized hot spots. As the fluid passes through the PCM-filled heat sink, it absorbs the PCM's latent heat, bringing the temperature closer to the optimal range for the cells. This reduces temperature gradients between cells and improves overall battery performance.

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Battery module with adjustable cell constraining pressure to uniformly enhance high-rate performance across cells in varying temperature regions. The module has multiple submodules with cell stacks. Inside the housing, some submodules have lower constraining pressure than others when temperature is low. This prevents high-temperature cells from having excessively high resistance, allowing all cells to have similar high-rate resistance. A mechanism adjusts constraining pressure based on temperature. This compensates for temperature variation inside the module.

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Lithium ion battery with improved rate and low-temperature performance by using solid electrolyte particles with specific ions away from the active material particles. The battery has an electrode with an active material layer containing lithium ion conductive particles, and a separate solid electrolyte layer with particles having a different first ion. The first ion is an alkali metal ion like K, Ca, Mg, or Al. This configuration allows better ion desolvation and transport compared to having the same ions in both layers. The separated solid electrolyte layer avoids competition for solvent molecules with the active material particles.

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Composite solid electrolyte for lithium batteries that improves performance and safety over conventional liquid electrolytes. The composite solid electrolyte contains a solid polymer like PEO, dispersed bilayer phyllosilicate nanoparticles like halloysite, and dissolved lithium salt. The nanoparticles and salt are distributed in the polymer to enhance conductivity and diffusivity. The composite electrolyte can be formed as a thin film. It provides better low-temperature performance and stability compared to PEO-only electrolytes. The nanoparticles and salt improve ionic transport and reduce crystallization. The composite electrolyte enables solid-state batteries with improved safety over liquid electrolytes due to reduced flammability and leakage.

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Non-aqueous electrolyte for lithium batteries that can be used over a wide temperature range (-40°C to 60°C) without freezing. The electrolyte composition allows the battery to operate in extreme cold without solidifying. The electrolyte contains specific proportions of chain carbonates like ethylene carbonate, propylene carbonate, dimethyl carbonate, and fluorinated chain ester or ethyl propionate. The carbonate mix provides the required freezing point depression and conductivity for cold temperature performance. The fluorinated chain ester improves voltage withstand.

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Secondary battery with improved performance at low temperatures and lifetime at high temperatures. The battery has an inorganic solid-containing layer between the positive and negative electrodes. The layer contains a mixed solvent of fluorinated carbonate and fluorinated ether, lithium salt, and inorganic solid particles. This layer improves battery performance at low temperatures by preventing electrolyte solidification and electrode reactions. It also improves high temperature lifetime by reducing electrode degradation from the electrolyte.

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A method to make oxide solid-state batteries with improved capacity by lowering the sintering temperature and preventing cathode degradation during solid-state battery formation. The method involves using a composite oxide cathode, lithium lanthanum zirconate solid electrolyte, and a lower melting point lithium salt. By laminating and heating these components, the solid electrolyte sintering temperature is lowered. Adding a hydroxide to the cathode mixture neutralizes acid generated during solidification to prevent cathode degradation. This allows forming the solid-state battery at lower temperatures without cathode capacity loss.

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Solid electrolyte for lithium batteries that enables high performance at low temperatures. The electrolyte composition is a phosphate oxide with the general formula Li1+2xM12-x(Ca1-yM2y)x(PO4)3 where M1 is Zr or Hf, M2 is Sr or Ba, and 0<x<2, 0<y<=1. This composition provides stable chemical compatibility between the electrode and electrolyte, high lithium ion conductivity at low temperatures, and low cost. It enables lithium batteries with good discharge rate performance at temperatures below room temperature. The batteries can be used in applications like electric vehicles that require high capacity and low temperature operation.

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Electrolyte solution and battery for non-aqueous electrolyte batteries that have improved low-temperature performance, cycle life, and storage stability. The electrolyte contains specific silane and fluorine-containing compounds. The silane compound, represented by a general formula with an Si-X bond (X is F or O), improves low-temp performance. The fluorine-containing compound, represented by general formulas with P-F or S-F bonds, improves cycle life and storage stability at high temperatures. Using both compounds together provides optimal performance.

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Electrode for solid-state batteries with a temperature-dependent resistor layer to prevent overheating without degrading battery performance. The electrode has a PTC (positive temperature coefficient) resistor layer sandwiched between the active material and current collector. The PTC layer contains an insulating inorganic substance and a conductive polymer. The insulating substance ratio near the active material is lower than further from the active material. This prevents high resistance at room temp while maintaining high resistance at high temps. The PTC layer contacts the active material well at low temps but separates at high temps for overheating prevention.

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Solid catholyte material for solid state batteries with improved ionic conductivity for higher mass loading, faster charge/discharge, and wider temperature range compared to conventional catholytes. The solid catholyte contains a lithium-germanium-phosphorus-sulfur (LGPS) or lithium-silicon-phosphorus-sulfur (LSPS) composition in a polycrystalline state. The catholyte has an oxygen species ratio of 1:2 or less to form LGPSO or LSPSO. This configuration enhances ionic conductivity compared to pure LGPS/LSPS. A protective layer over the catholyte prevents reaction with the active material. The solid catholyte confined between active regions allows higher loading, faster charge/discharge, and wider temperature range compared to liquid electrolytes.

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