Techniques to Increase Energy Density of Sodium-Ion Batteries for EVs

A sodium ion battery system with adjustable driving force for electric vehicles that allows modular replacement and force adjustment of individual battery cells without dismantling the entire battery pack. The system uses a sodium ion battery structure with multiple shells, each containing a sodium ion battery cell. A controller connects to the battery structure and a separate drive structure with a motor. The battery and motor are isolated. This allows swapping faulty cells or adjusting motor power without replacing the entire battery pack. The drive structure has a shaft, bracket, iron core, end plates, wiring, magnetic steel, and hub.

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Secondary battery with improved cycle performance and storage life through novel electrode design. The battery comprises a positive electrode plate with a current collector and active material, and a negative electrode plate with a current collector. The positive electrode active material comprises a combination of lithium and sodium ions, with the sodium ion active material having a lower charging voltage than the lithium ion active material. The battery features a unique current collector material that prevents sodium metal deposition during charging, while maintaining the necessary overpotential for electrolyte formation. The battery cell is formed by stacking the current collectors, isolating membrane, and positive and negative electrode sheets, and then sealing the cell through processes such as baking and sealing.

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A battery cell combining sodium-ion and lithium-ion electrodes in a single cell structure. The cell comprises a composite electrode assembly comprising a sodium-ion positive electrode sheet, a lithium-ion positive electrode sheet, and a separator. The electrodes are arranged in a specific pattern to achieve optimal performance characteristics. The cell features a diaphragm separating the electrodes, with the negative electrode comprising a sodium-ion active material and the positive electrode comprising a lithium-ion active material. The cell can be configured to operate at various charge levels (0.005 to 200 times C), offering enhanced performance compared to traditional battery pack configurations.

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Lithium-sodium dual-ion battery with enhanced performance through a novel electrode material combination. The battery comprises a positive electrode made from a sodium-based material (e.g., Ni0.33Fe0.33Mn0.33O2) and a lithium-based material (e.g., LiFePO4), while the negative electrode is made from a graphite-based material (e.g., graphite-hard carbon composite). The electrodes are prepared through a specific slurry formulation that balances the sodium and lithium content. The battery cell is assembled into a button-type configuration with a separator and electrolyte, and the electrodes are compacted to achieve optimal density.

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Sodium ion batteries achieve higher energy density through novel negative electrode materials. The invention introduces a negative electrode comprising a sodium metal oxide, where the metal oxide is specifically designed to enhance the negative electrode's performance while maintaining safety. This material combines the benefits of sodium metal with the advantages of oxide materials, enabling significant improvements in energy density compared to conventional negative electrodes.

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Sodium ion battery design with improved cycle life and energy density for sodium ion batteries used in energy storage applications. The design involves a specialized negative electrode structure with a separate sodium storage layer and conductive skeleton layer. The sodium storage layer provides the sodium intercalation capacity, while the conductive skeleton layer promotes uniform sodium deposition and prevents dendrite growth. The capacity ratio of the sodium storage layer to the positive electrode layer is controlled to optimize energy density and cycle life.

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Hybrid lithium-sodium battery with enhanced safety, energy density, and power density through the integration of sodium-ion battery positive electrode materials with lithium-ion battery positive electrode materials. The battery employs a hybrid design where sodium-ion battery materials are combined with lithium-ion battery materials in the positive electrode, creating a cathode that balances safety, energy density, and power density benefits. The positive electrode materials incorporate conductive additives, current collectors, and other components to optimize performance while maintaining safety.

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A sodium-ion battery cathode material comprising a positive electrode active material comprising a combination of NaFePO4 and NaFeP2O7, with particle size distribution of 3-8.5 μm. The material combines the high capacity and rate performance of NaFePO4 with the improved stability and mechanical properties of NaFeP2O7.

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Hybrid battery pack that combines the high energy density of lithium-ion cells with the low cost and high temperature performance of sodium-ion cells. The pack features an array structure comprising both types of cells, where the lithium-ion cells are connected in series and the sodium-ion cells are connected in parallel. This arrangement enables the lithium-ion cells to maintain their high charge and discharge capacity even at extreme temperatures, while the sodium-ion cells provide their unique benefits of high thermal stability and rapid charging capabilities. The pack's architecture allows the lithium-ion cells to be directly connected to the sodium-ion cells, eliminating the thermal management challenges typically associated with lithium-ion battery pack assembly.

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High energy density, high power rechargeable lithium metal batteries with over 1000 Wh/L and 350 Wh/kg energy densities that can discharge at 1C or higher rates. The batteries have thin lithium metal anodes, thick cathodes, hybrid separators, and liquid/solid electrolytes. The thin lithium anodes have excess cathode capacity. This allows high anode utilization and energy density. The hybrid separator combines a porous polymer layer with a protective coating to prevent dendrite growth. The electrolyte is stable at high cathode voltages. The batteries have over 1 Ah capacity, fast charge/discharge, and long cycle life.

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Flexible sodium-ion battery negative electrode comprising carbon nanotube film as current collector, and nickel sulfide negative electrode material grown on the carbon nanotube film in-situ. The negative electrode achieves high performance through the unique combination of carbon nanotube film's high surface area and excellent mechanical properties, while the nickel sulfide material's high sodium storage capacity and mechanical stability enable reliable performance across repeated bending cycles.

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Lithium-sodium composite dual-ion battery with improved energy density and resource abundance compared to traditional lithium-ion batteries. The battery has a heterogeneous two-sided structure where one side of the positive electrode contains lithium-based material and the other side contains sodium-based material. The negative electrode has graphite on one side and hard carbon on the other. This allows lithium and sodium ions to intercalate separately in the two-sided heterogeneous electrodes. The battery uses an electrolyte containing both lithium and sodium salts to enable ion transport.

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Sodium-ion battery positive plate with enhanced electrical conductivity through optimized binder distribution. The plate comprises a positive current collector with a surface featuring a specific binder concentration, and a positive active material arranged on this surface. The binder concentration is precisely controlled to achieve optimal conductivity while maintaining the positive electrode's non-oxidizable nature. The negative electrode current collector also features a controlled binder concentration, with both foil and rubber emulsion options available. This configuration enables the positive plate to achieve high electrical conductivity while maintaining the negative electrode's safety characteristics.

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Polyanionic sodium-ion battery cathode material with improved performance and scalability. The material is a single-phase or two-phase sodium ion battery cathode made from a novel liquid-phase preparation method that enables precise control of metal phosphate composition through citric acid complexation. The method ensures uniform distribution of metal ions during solution preparation, eliminating common issues associated with traditional solid-phase ball milling. The resulting material exhibits excellent electrochemical performance, stability, and reproducibility, making it suitable for large-scale production.

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Sodium-ion battery with improved energy density through the use of high-density sodium metal clusters as negative electrodes. The battery employs a novel negative electrode material, specifically hard carbon, which enables the formation of sodium metal clusters through controlled intercalation. This material's unique properties, including its high true density and extensive sodium intercalation void space, allow for efficient sodium ion storage and release. The battery design combines the hard carbon material with a conductive agent and binder to create a robust and efficient negative electrode system.

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Battery with enhanced power density through improved electrode interface properties. The battery comprises a positive electrode sheet, a negative electrode sheet, and a separator. The positive electrode sheet contains a positive electrode current collector and a positive electrode coating, while the negative electrode sheet includes a negative electrode current collector and a negative electrode coating. The negative electrode current collector features a network of holes with diameters ranging from 50 to 400 micrometers and spacings of 0.5 to 1 millimeter. This unique electrode architecture enables controlled lithium ion intercalation and transfer while maintaining high power density.

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Trivalent sodium ion doping of mixed sodium iron pyrophosphate cathode materials for sodium-ion batteries, where the doping replaces divalent iron ions. The material combines trivalent sodium-doped mixed sodium iron pyrophosphate with in-situ carbon coating, resulting in a material with enhanced conductivity and surface properties.

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A mixed crystal polyanionic phosphate cathode material for sodium-ion batteries with enhanced electrochemical performance. The material comprises sodium iron phosphate, sodium iron pyrophosphate, and sodium iron phosphate with micro- and nanostructured macropores and mesopores, achieving high specific capacity and long cycle life. The material's unique microstructure enables efficient sodium ion migration through its porous network, while maintaining structural integrity.

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Aqueous sodium-based mixed ion secondary battery that achieves higher energy density and better cycle performance compared to traditional single-ion batteries. The battery employs a layered structure with sodium manganate as the anode material, where sodium ions intercalate and desorb through layered intercalation and deposition reactions. The negative electrode is composed of a metal oxide, with additional conductive carbon and binder materials. The electrolyte is a saturated metal oxide solution in a sodium hydroxide solution. The battery's unique design enables simultaneous ion storage and release through the layered structure, resulting in improved performance characteristics.

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Modified iron-based polyanionic compound positive electrode material for sodium-ion batteries, comprising graphene supported on the surface of the modified iron-based polyanionic compound. The material combines the high electronic conductivity and reversible discharge capacity of iron-based polyanions with the enhanced mechanical stability and surface area of graphene. The material achieves improved performance in sodium-ion batteries through its optimized surface structure.

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