Sodium-ion intercalation in graphite presents significant challenges due to thermodynamic instability. While lithium ions readily intercalate between graphene layers with interlayer spacing of 3.35Å, sodium ions, with their larger ionic radius of 1.02Å (versus lithium's 0.76Å), face substantial energy barriers. Experimental measurements show sodium-graphite compounds typically achieve specific capacities below 35 mAh/g—dramatically lower than lithium-graphite's 372 mAh/g theoretical capacity.

The fundamental challenge lies in designing electrode materials and architectures that can accommodate sodium's larger ionic radius while maintaining the structural integrity and electronic conductivity needed for practical energy storage applications.

This page brings together solutions from recent research—including carbon-based negative electrodes for uniform ion distribution, Na-Sn-Al-O structured surfaces for controlled sodium release, glass fiber separators with oxidation ball-milled sodium ion conductor coatings, and hybrid lithium-sodium battery approaches. These and other approaches demonstrate promising pathways to overcome the intercalation limitations that have constrained sodium-ion battery development for electric vehicle applications.

1. Semi-Solid Sodium Ion Battery Electrode with Na-Sn-Al-O Structured Surface for Controlled Sodium Release

SHANDONG ZHAOWEN NEW ENERGY TECHNOLOGY CO LTD, 2025

A semi-solid sodium ion battery electrode material that enhances cycle performance through controlled sodium release. The material comprises a hard carbon negative electrode sheet with a pre-sodiumized surface, where a Na-Sn-Al-O structure is formed to facilitate stable sodium release. This structure enables rapid sodium ion migration through the electrode, preventing dendrite formation and electrolyte consumption. The material is prepared through a controlled electrolyte treatment process that creates a uniform Na-Sn-Al-O layer on the electrode surface. The resulting material exhibits improved cycle performance compared to conventional methods, with enhanced sodium storage capacity and energy density.

2. Sodium-Ion Battery Management System with Environmental Assessment and Predictive Analytics for Electrode Material Selection

SHENGMATE ENERGY CO LTD, Saintmart Energy Co., Ltd., 2024

Sodium-ion battery management system for optimizing performance and lifespan through advanced monitoring and predictive analytics. The system employs environmental assessment to identify optimal electrode materials for sodium-ion batteries, enabling precise selection of materials that balance performance, safety, and environmental sustainability. It also analyzes battery health data and user behavior to provide personalized recommendations for maintaining optimal operating conditions, predicting potential degradation, and identifying areas for improvement.

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3. Sodium-Ion Battery Management System with Advanced Monitoring and Predictive Analytics for Charge-Discharge Data Analysis

SHENGMATE ENERGY CO LTD, 2024

Sodium-ion battery management system for optimizing performance and lifespan through advanced monitoring and predictive analytics. The system analyzes charging and discharge data to assess battery health, identifies usage patterns, and provides personalized recommendations for optimizing charging and discharging cycles. This enables users to extend the battery's lifespan by optimizing charging and discharging conditions, while maintaining optimal performance.

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4. Sodium-Ion Battery with Layered Oxide and Polyanion Cathode Blending for Enhanced Structural Integrity

JIANGSU HIGEE NEW ENERGY CO LTD, 2024

A long-life sodium-ion battery that achieves superior performance through precise material blending and optimized electrode preparation. The battery combines layered oxide positive electrodes with polyanion cathodes, where the polyanion material is specifically selected to balance reversible capacity, electronic conductivity, and compaction density. The precise blending ratio of polyanion to layered oxide materials ensures optimal performance while maintaining structural integrity. The prepared battery achieves high energy density and long cycle life through careful material selection and preparation, enabling reliable operation over thousands of charge/discharge cycles.

5. Glass Fiber Separator with Oxidation Ball Milled Sodium Ion Conductor Coating

UNIV JILIN, 2024

Separator for sodium-ion batteries that suppresses dendrite growth through a novel ion conductor coating process. The separator is prepared through a solid-phase synthesis method where a precursor material, Na2cO3·SiO2·Sm2O3, is mixed with a binder to create a glass fiber separator. The precursor material undergoes oxidation ball milling to produce a sodium ion conductor coating, which is then applied to the separator through tape-casting. This coating significantly improves the separator's ability to prevent sodium dendrite growth during battery assembly.

6. Sodium-Ion Battery with Carbon-Based Negative Electrode for Uniform Ion Distribution

CONTEMPORARY AMPEREX TECHNOLOGY CO LTD, 2024

Sodium-ion batteries with improved cycling performance through the use of carbon-based materials in the negative electrode. The battery design incorporates a carbon-based active material in the negative electrode current collector, which enables more uniform sodium ion distribution during charging and discharging. The carbon-based material, such as carbon nanotubes or graphene, replaces traditional graphite or graphene, offering improved electrochemical properties. The sodium-ion battery architecture remains similar to traditional lithium-ion batteries, with the negative electrode current collector and separator forming the battery cell.

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7. α-NaVOPO4 Coated Cathode Material for Sodium-Ion Batteries and Synthesis Method

ZHEJIANG POWER NEW ENERGY CO LTD, 2023

α-NaVOPO4Coated sodium-ion battery cathode material and preparation method thereof, sodium-ion battery technical field.

CN117038996A-patent-drawing

8. Hybrid Lithium-Sodium Battery with Composite Positive Electrode Materials

FUDAN UNIVERSITY, 2023

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.

9. Lithium-Sodium Mixed Ion Battery with Nano-Diamond-Modified Separator and Alloy Counter Electrode

UNIV JILIN, 2023

A lithium-sodium mixed ion battery with improved capacity, cycle stability, and rate capability compared to conventional lithium-ion or sodium-ion batteries. The battery uses a lithium-sodium alloy counter electrode, lithium-sodium mixed electrolyte, and a nano-diamond-modified separator to enable co-storage of lithium and sodium ions. This allows higher capacity, as graphite anodes can now store both lithium and sodium ions. The nano-diamond modification further enhances performance. The battery assembly involves a graphite negative electrode, lithium-sodium mixed electrolyte, separator, and either a lithium-sodium alloy counter electrode or a lithium-sodium salt positive electrode.

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10. Sodium-Ion Battery with Prussian Blue Cathode Featuring Controlled Coordination Water Release

SHANGHAI HANXING TECH CO LTD, 2023

A sodium-ion battery comprising a Prussian blue cathode with improved stability and cycle performance through controlled release of coordination water. The cathode contains a sodium salt dissolved in an organic solvent, with additives such as organic solvents, electrolytes, and conductive materials. The sodium salt composition is optimized to maintain a stable water content within the Prussian blue crystal structure, preventing premature deintercalation and degradation. This controlled water release enables the cathode to maintain its structural integrity while providing enhanced capacity and cycle performance compared to conventional sodium-ion batteries.

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11. Aqueous Lithium-Sodium Ion Battery with Graphite-Based Composite Film Current Collector and Conductive Carbon-Coated Titanium Phosphate Anode

Jiangsu University of Technology, JIANGSU UNIVERSITY OF TECHNOLOGY, 2022

Aqueous lithium-sodium ion battery with improved performance through a novel current collector design. The battery employs a graphite-based composite film as the current collector, which is prepared through a hydrothermal method. The composite film is combined with a conductive carbon coating on the titanium phosphate anode, which enhances conductivity and prevents water peeling. The battery achieves enhanced cycle life, high rate capability, and improved energy density compared to conventional designs.

12. Carbon-Based Sodium Vanadium Fluorophosphate Electrode with Surface-Functionalized Modification via Controlled Solution Processing

NORTHEAST NORMAL UNIVERSITY, 2021

A positive electrode material for sodium-ion batteries that combines high cycle performance with excellent thermal stability. The material comprises a carbon-based active material, specifically sodium vanadium fluorophosphate, which is modified with surface functionalization. The modified material is prepared through a controlled solution processing method that involves stirring the dark blue solution for 0.5 hours during reflux, followed by a subsequent calcination step. This surface modification enhances the material's electrical conductivity while maintaining its thermal stability, enabling superior performance in sodium-ion batteries compared to conventional materials.

13. Method for Forming Coated Sodium Ion Battery Cathode Material via Metal Precursor Solution and Calcination

ZHEJIANG NATRIUM ENERGY CO LTD, 2021

A method for preparing a sodium ion battery cathode material with improved electrochemical performance through surface coating. The method involves dissolving metal precursors in a volatile solvent to form a solution/suspension, then mixing the solution with sodium ion battery cathode material or precursor, and finally calcining the mixture to form a coated cathode material. The coating process prevents direct contact between the cathode material and electrolyte while maintaining the material's specific capacity and structural integrity.

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14. Spinel Oxide Anode Material Comprising Co2SnO4 for Sodium-Ion Batteries

KOREA INSTITUTE OF SCIENCE AND TECHNOLOGY, 2020

Anode active material for sodium-ion batteries with improved capacity compared to existing materials. The anode uses a spinel oxide made from cobalt and tin. The spinel composition is Co2SnO4, represented by the chemical formula Co2SnO4. The spinel structure allows fast sodium ion diffusion for better cycling performance. The anode material is made by precipitating cobalt and tin precursors, filtering, drying, and heat treating.

15. Cobalt Tin Spinel Oxide Anode Material with Enhanced Sodium-Ion Intercalation Properties via Precipitation Process

KOREA INST SCI & TECH, 2019

An anode material for sodium-ion batteries that achieves high capacity through a simple precipitation process. The material comprises cobalt tin spinel oxide, which exhibits superior sodium-ion intercalation properties despite its large size. The material's unique spinel structure enables stable charge/discharge behavior, with high capacity retention even after multiple charge cycles. The material's performance is comparable to that of conventional lithium-ion anodes, but with lower cost and environmental impact.

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16. Negative Electrode with Cobalt-Tin Precursor Derived Active Material for Sodium-Ion Batteries

KOREA INSTITUTE OF SCIENCE AND TECHNOLOGY, 2019

Negative electrode for sodium-ion batteries that achieves high capacity through a simple precipitation method. The active material is prepared by controlling the ratio of cobalt and tin precursors, with the precipitate being filtered, dried, and heat-treated. The resulting material exhibits excellent capacity characteristics, including high charge/discharge rates and specific capacities, making it suitable for sodium-ion batteries.

17. Electrochemical Cell with Metallic Sodium Anode and Dendrite-Free Cathode Utilizing High-Salt Ammonium-Based Electrolyte

BROADBIT BATTERY OY, 2018

Rechargeable electrochemical cells utilizing an anode containing metallic sodium, featuring a novel cathode that supports high energy density and these particular electrodes. The cathode comprises a current collector material that supports essentially smooth, dendritic crystal-free, and well-adhered electrochemical precipitation of sodium. The electrolyte is a high-salt liquid ammonium-based superalkali, which is compatible with metallic sodium anodes and exhibits a high potential window up to 2.75V with respect to / Na. The cathode material is specifically designed to support stable cycle conditions, while the electrolyte provides the necessary precipitation window for sodium anode cycling.

18. Amorphous Sodium Vanadium Phosphate Composite with Hydrothermal and Carbothermal Synthesis Method

UNIV QILU TECHNOLOGY, 2018

Amorphous sodium vanadium phosphate (NaV0P04) for sodium-ion battery anode material and preparation method. The material combines sodium vanadium phosphate with phosphorus and vanadium sources, synthesized through hydrothermal and carbothermal reduction. The resulting amorphous NaV0P04/C exhibits enhanced electrochemical performance for sodium-ion batteries.

19. Carbon-Based Electrode with Conductive Titanium Oxide Coating for Enhanced Surface Charge Transfer

IUCF HYU, 2018

Carbon-based negative electrode for lithium-ion batteries that enables rapid charging and discharging through surface charge transfer enhancement. The electrode is made from a carbon-based material with a conductive titanium oxide (TiO) coating applied to its surface. The TiO layer improves charge transfer between the electrode and the electrolyte, allowing for faster charging and discharging rates compared to conventional electrodes. The electrode can be made from graphite, hard carbon, or soft carbon, and the TiO coating can be applied at various concentrations.

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20. Controlled Carbon Incorporation into Hydrothermally Synthesized Titanium Dioxide Nanoparticles for Sodium-Ion Battery Electrodes

IUCF-HYU, 2017

Method for enhancing sodium-ion battery performance through controlled carbon incorporation into titanium dioxide nanoparticles. The method involves hydrothermally synthesizing titanium dioxide nanoparticles, then uniformly coating them with a carbon precursor to form a composite material. The carbon precursor is selectively incorporated into the titanium dioxide surface, preventing particle growth and maintaining uniform coating. This composite material exhibits superior electrochemical properties, including enhanced conductivity and capacity retention, compared to conventional sodium-ion battery electrodes.

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