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2026-04-21
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Li-Ion Battery Technology
Patent Highlights – Free Version

Ionic plastic crystals softening Li6PS5Cl solid electrolyte layers for low-pressure sulfide cells, silane-free magnesiothermic synthesis of silicon-carbon composite anodes, and ternary blends of single- and secondary-particle NMC with LMFP cathodes

Prospective High Impact Advancements

⚡
Electrolytes
Solid & Semi-Solid
Samsung SDI
SBPCFSI (spiro-ammonium fluorosulfonimide salt) ionic plastic crystal with 10 mol% LiTFSI in Li6PS5Cl / PVDF solid electrolyte layer (96.5 : 1 : 2.5 mass ratio) for stable cycling at 0.3 MPa stack pressure
Retention: 93.2% @100 cycles
LG Energy Solution
Co-rolling dry-process fabrication of a Li6PS5Cl / PTFE solid electrolyte layer on a single-crystal LiNi0.82Co0.11Mn0.07O2 (5 mAh/cm2) positive electrode
Stack-level: 310 Wh/kg, 805 Wh/L
Hydro Quebec
Star-shaped polyether + PVDF-HFP blend with LiTFSI, TEGDME plasticizer, and dicationic ionic additive cast onto 9.6 μm PET nonwoven scaffold
Young's modulus: 49.4 MPa
−
Anode
Negative Electrode
Sila Nanotechnologies
Magnesiothermic reduction of porous SiO2 microspheres (remote Mg source, 600°C, 2 kPa, 8 h) with propylene CVD carbon termination and sealing layers
Reversible capacity: 2,497 mAh/g, FCE 89.6%
Leydenjar Technologies
PECVD silicon anode with reduced silane / plasma power ratio (0.078 sccm/W) yielding low Si–Si bond angle distortion (9.07°) measured by Raman spectroscopy
Cycle life: 170 cycles @80% retention
Hunan Shinzoom
In-situ AlF3 coating (0.2 mass%) on silicon-carbon composite via choline chloride / trifluoroacetamide deep eutectic solvent with dissolved AlCl3
Retention: 90.0% @28 days, 60°C
+
Cathode
Positive Electrode
SK on
Ternary blend of secondary-particle (D50: 13 μm) and single-particle (D50: 3 μm) NMC88 with LMFP (D50: 1 μm) at 49 : 21 : 30 mass%
Retention: 92.5% @500 cycles, 45°C
BASF Shanshan
Two-step W + Sr sintering of Ni-rich NMC forming 5–16.5 nm Li-containing perovskite LiWSr2O5.5 surface coating via Li-deficient intermediate
Retention: 95.5% @1000 cycles, 45°C
Toyota
P2-to-O2 ion exchange synthesis of plate-shaped Li1.0Mn0.4Ni0.2Co0.4O2 with reduced D50 (5.42 μm) via increased spray-dry atomizing pressure
Init. capacity: 244 mAh/g @0.1 C discharge
Benchmarking Experiments in Patents ⓘ
These benchmarks are drawn directly from experiments reported in the patents, where an inventive example incorporating the claimed innovation is compared against a comparative example that omits it while keeping the cell configuration, chemistry, and test conditions otherwise equivalent.
Capacity Retention at Low Stack Pressure with Ionic Plastic Crystal (Samsung SDI)
93.2%
10.1%
SBPCFSI (spiro-ammonium fluorosulfonimide salt) ionic plastic crystal + 10 mol% LiTFSI in Li6PS5Cl / PVDF solid electrolyte layer (96.5 : 1 : 2.5 mass ratio) vs. Li6PS5Cl / PVDF without plastic crystal • 100-cycle capacity retention, Li2O-ZrO2-coated LiNi0.8Co0.15Mn0.05O2 / Ag-C cells, 0.3 MPa stack pressure, 2.5–4.25 V, 25°C
Extended Cycle Life via Tuned PECVD Silicon Atomic Structure (Leydenjar Technologies)
170 cycles
109 cycles
Silane / plasma power ratio of 0.078 sccm/W yielding Si–Si bond angle distortion of 9.07° vs. 0.469 sccm/W yielding Si–Si bond angle distortion of 9.71° • cycles to 80% capacity retention, lithium-ion cells with ≥90 mass% Si PECVD anode
Reduced Autoclave Pressure with Ternary NMC88 + LMFP Blend (SK on)
0.32 bar
2.99 bar
Blend of secondary-particle NMC88 (D50: 13 μm), single-particle NMC88 (D50: 3 μm), and LMFP (D50: 1 μm) at 49 : 21 : 30 mass% vs. 100 mass% secondary-particle LiNi0.88Co0.10Mn0.02O2 • maximum autoclave pressure on heating 30–50 Ah pouch cells from 4.2 V to 0 V in a 1000 L autoclave (lower is better)
High-Temperature Cycle Retention with LiWSr2O5.5 Perovskite Coating (BASF Shanshan)
95.5%
87.3%
Three-stage first sintering with W (1.2 mass%) + Sr (1 mass%) forming LiWSr2O5.5 perovskite coating via Li-deficient intermediate vs. W at 0.3 mass% (insufficient to form perovskite coating) • 1000-cycle capacity retention at 1 C charge / 1 C discharge, 45°C, 1.5 Ah graphite / NCM69 pouch cells, 2.8–4.4 V

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

🏢
USA
Ampcera
Technology Assessment: Can a single solvent-free spray platform deposit dense, moisture-sensitive argyrodite layers across an entire cell stack at production throughput? The chapter examines how cold and thermal spray position against conventional slurry processing barriers, how near-term electrolyte material supply complements longer-term cell commercialization, and how the patent portfolio's scope compares with public positioning on performance.
Product Development Pathway
(5 R&D Concepts)
Lattice-engineered argyrodite electrolyte approach using chalcogen-based defect incorporation to suppress bulk electronic conductivity and raise critical current density for dendrite resistance at the lithium metal interface. Solvent-free energy-assisted spray manufacturing platform applying cold and thermal spray deposition to form binder-free electrolyte and composite electrode layers directly onto current collectors in a continuous roll-to-roll-compatible sequence. Further concepts address dry-processed composite separator fabrication, cathode-catholyte interfacial impedance reduction, and gradient electrode architecture decoupling energy and power density within the composite electrode.
Key Synergies
Spray manufacturing platform and lattice-engineered electrolyte converging on a single solvent-free architecture – aligning separator, electrode, and full-stack formation into one sequence to jointly address cycle life, manufacturability, and production throughput.
🏢
Germany / China
BASF / BASF Shanshan
Technology Assessment: BASF positions as a materials supplier rather than a cell maker — a role demanding flexibility across diverse customer cell architectures. The chapter examines how the bilayer electrolyte approach balances oxidative and reductive stability demands, whether cross-compatible interface materials support architecture-agnostic integration, and how the patent portfolio's scope compares with public positioning.
Product Development Pathway
(5 R&D Concepts)
Bilayer electrolyte architecture pairing a glassy lithium aluminum oxychloride catholyte selected for oxidative stability with a sulfide argyrodite separator handling reductive-side functions, leveraging each electrolyte class's mechanical and electrochemical strengths. Cation-substituted chlorine-rich argyrodite sulfide electrolyte achieving enhanced ionic conductivity through simultaneous vacancy creation and halide sublattice tuning. Further concepts address high-nickel cathode surface stabilization through gradient doping and island coating, dual ion-and-electron conduction pathways at the cathode/sulfide interface, and self-terminating anode passivation for lithium metal compatibility across multiple electrolyte families.
Key Synergies
Cross-compatible electrolyte, cathode, and anode interface materials converging on a flexible supply portfolio — enabling customers to integrate complementary components across sulfide, halide, and hybrid cell architectures for balanced product launch viability.
🏢
USA
Blue Current
Technology Assessment: Blue Current positions as a fully dry sulfide composite developer targeting conventional Li-ion manufacturing equipment — with silicon-dominant anodes and pilot production already underway. The chapter examines how the argyrodite-polymer separator approach addresses competitive energy density, why thin electrolyte film formation remains a central scale-up question, and how public statements align with what the patent portfolio reveals about development priorities.
Product Development Pathway
(4 R&D Concepts)
In-situ sintering of argyrodite-polymer composite separators using ball-milled sulfide particles that fuse during hot-pressing within elastic hydrophobic polymer matrices, eliminating a separate calcination step and enabling thin-film formation on conventional Li-ion manufacturing equipment. Functionalized polymer binders for sulfide composite electrolytes engineered to maintain ionic conductivity at high inorganic loading while accommodating silicon anode volume expansion through elastomeric polymer chemistry with tunable functional group content. Further concepts address sulfide stability under ambient moisture exposure and manufacturing architecture for consistent multilayer cell integration with embrittlement-mitigating current collector interfaces.
Key Synergies
Material synthesis, binder engineering, and cell assembly concepts converging on a single fully dry architecture using conventional Li-ion equipment — aligning ionic conductivity, silicon volume accommodation, and sulfide safety mitigation for product launch viability.
🏢
USA
Corning
Technology Assessment: Corning positions as a garnet oxide film and process supplier rather than a standalone cell maker. Can continuous ribbon manufacturing meet the interface quality threshold that lithium metal solid-state cells demand? The chapter examines how the portfolio translates longstanding precision ceramics infrastructure into garnet production, how announced partnerships complement supply ambitions, and how the patent portfolio's scope compares with public positioning.
Product Development Pathway
(5 R&D Concepts)
Continuous ribbon manufacturing approach for garnet oxide electrolyte films using char-free binder chemistry that enables flameless burnout during inert-atmosphere sintering at the throughput required for commercial cell supply. Controlled surface porosity generation on sintered garnet electrolyte films through selective chemical treatment, creating a structural template that accepts subsequent anode interface treatments for improved solid-solid contact. Further concepts address lithium metal dendrite suppression at the anode contact, mechanical compliance accommodating volume changes during cycling, and cathode-side interfacial resistance reduction with high-temperature stability.
Key Synergies
Continuous manufacturing backbone paired with modular interface concept subsets — enabling a single oxide film platform to address energy-density, power, or cycling-robustness priorities through different combinations of interface treatments.