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Dec 16, 2025
Visual Summary

Li-Ion Battery Technology
Patent Highlights

Silicon seed layers for anode-free cells, porous Si clathrate selectivity and pore control for Si anodes, and buffer pore strategies for high-Ni cathodes

Overview

This cycle highlights anode-free solid-state architectures with 5× critical current improvements via silicon seed layers on copper, alongside 3D porous electrode designs and halide electrolyte interfacial engineering. Silicon anode precision advances through AlF3 particle size control for selective porous Si clathrate II formation, pore-volume correlations for cycling consistency, and PAN binder optimization. High-Ni cathode reliability progresses via polypropylene-templated buffer pores in particle cores, multi-element LMFP doping, and controlled Al heterogeneity in doped NMC.

Commercially Relevant Innovations by Category

Electrolytes
Solid & Semi-Solid
Anode-free cell with amorphous Si seed layer (500 nm) on Cu
Jcrit: 5.0 mA/cm2
3D porous cathode with oriented carbon-coated sidewalls
Full electrode utilization
Y-halide electrolyte heat treatment creates Y-rich protective layer
Halide-Li interface stability
Anode
Negative Electrode
Selective porous Si clathrate II via controlled AlF3 particle size (D50: 56 μm)
Ratio: 14.0 (porous Si clathrate II/I)
Pore-volume-controlled Si-C via (Si/C)×P1 ratio optimization
Retention: 83% @150 cyc
Unmodified PAN binder (no cyclization) for Si-C composite
Life: >1300 cyc
+
Cathode
Positive Electrode
Polypropylene-templated buffer pores in high-Ni NCM core
Capacity: 210 mAh/g
Multi-doped LMFP (≥3 elements from Al/B/Co/Mg/Ni)
Retention: 99.7% @30 cyc
Spray pyrolysis for controlled Al heterogeneity in high-Ni NCM
Capacity: 216 mAh/g
Key Comparative Benchmarks
1.0
5.0
+400%
Si seed layer (500 nm) vs. bare Cu mA/cm2 in LiPON cells
Si Clathrate Selectivity (Toyota)
0.7
14.0
+1789%
Classified AlF3 (D50: 56 µm) vs. uncontrolled particle size porous Si clathrate II/I ratio
Si-C Retention Consistency (NEXEON)
69-81%
83%
Stable
Pore-volume control ((Si/C)×P1 ratio) vs. high-Si baseline retention at 150 cycles, improved consistency
PAN Binder Cycle Life (Sionic)
1100
1300
+18%
Unmodified PAN (no cyclization) vs. cyclized PAN cycles to 80% capacity
High-Ni NCM Retention (L&F)
92.1%
96.3%
+4.6%
Polypropylene-templated buffer pores vs. standard synthesis retention at 50 cycles, 45°C
High-Ni NCM DC Resistance (BTR)
25
15
−40%
Spray pyrolysis – heterogeneous Al dopant distribution vs. mechanical mixing Ω (lower is better)

Recently Published Company Chapters
(Solid-state / Semi-solid Li-ion Battery Innovation & Patent Review)

🏢
South Korea
Samsung
Product Development Pathway
Dual-track approach: Sulfide electrolytes for EVs combining bulk conductivity optimization through doping, interface engineering with halide coatings, stratified membrane architectures, and scalable spray pyrolysis manufacturing. Oxide electrolytes for microscale electronics leveraging metal-doped glass systems, dual-layer electrolyte architectures, and low-temperature co-sintering processes.
Key synergies between R&D concepts (oxides): Well-rounded bulk electrolyte + manufacturing scalability + co-sintered edge isolation regions
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Japan
Toyota
Product Development Pathway
Sulfide/halide electrolytes emphasizing manufacturing quality control through atmospheric management, moisture resistance via surface modification, multi-layer interface stabilization strategies, and protective coating systems. Oxide electrolytes utilizing flux-mediated synthesis methods, compact-porous bilayer structures, carbon-coated porous layers, and stress-managed bipolar architectures.
Key synergies between R&D concepts (sulfides/halides): Consistent ionic conductivity + environmental stability + cathode interface electrochemical stability
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China
BYD
Product Development Pathway
Sulfide electrolytes featuring multi-element bulk modification for mechanical property tuning, pseudohalogen surface engineering for solvent compatibility, phosphide-sulfide bilayer interfaces, composite membrane reinforcement with structural fillers, and plasma-modified binder systems for processing optimization. Polymer electrolytes incorporating ionic liquid designs, electrochemical safety mechanisms, and mixed ionic-electronic conductors.
Key synergies between R&D concepts (sulfides): Mechanical bulk properties + surface degradation protection + lithium metal interface stabilization
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