Methods of increasing battery cycle life

Patent metadata

Field	Value
Publication number	US-2026031324-A1
Application number	US-202519279162-A
Country	US
Kind code	A1
Filing date	Jul 24, 2025
Priority date	Jul 24, 2024
Publication date	Jan 29, 2026
Grant date	—

Abstract

A method for extending battery cycle life of Li-ion battery includes executing a fast formation protocol on a Li-ion battery cell (cell) such that an induced Li loss shifts an electrode-specific utilization range with a lithiation level of the positive electrode decreased to be less than or equal 94% as determined via differential voltage analysis. Also, the fast formation protocol of the cell includes charging the cell to a maximum charging voltage of the cell in less than 2 hours during a first formation cycle and avoiding a kinetically limited region of the positive electrode.

First claim

What is claimed is:

1 . A method for increasing battery cycle life of Li-ion battery, the method comprising:
executing a fast formation protocol on a Li-ion battery cell (cell) such that an induced Li loss shifts battery electrode-specific utilization range after formation with a lithiation level of a positive electrode of the cell decreases to be less than or equal 94% as determined via differential voltage analysis, the fast formation protocol of the cell comprising charging the cell to a maximum charging voltage of the cell in less than 2 hours during a first formation cycle and avoiding a kinetically limited region of the positive electrode.

2 . The method according to claim 1 , wherein the lithiation level of the positive electrode is decreased to be less than or equal 92% as determined via differential voltage analysis.

3 . The method according to claim 2 , wherein the lithiation level of the positive electrode is decreased to be less than or equal 90% as determined via differential voltage analysis.

4 . The method according to claim 1 , wherein the lithiation level of the positive electrode is decreased to be less than or equal 94% and greater than or equal to 90% as determined via differential voltage analysis.

5 . The method according to claim 1 , wherein the fast formation protocol of the cell comprises charging the cell to the maximum charging voltage of the cell in less than 1.5 hours during the first formation cycle and avoiding the kinetically limited region of the positive electrode.

6 . The method according to claim 1 , wherein the fast formation protocol of the cell comprises charging the cell to the maximum charging voltage of the cell in less than 1 hour during the first formation cycle and avoiding the kinetically limited region of the positive electrode.

7 . The method according to claim 1 , wherein the fast formation protocol of the cell comprises charging the cell to the maximum charging voltage of the cell in less than 0.5 hours during the first formation cycle and avoiding the kinetically limited region of the positive electrode.

8 . The method according to claim 1 , wherein the lithiation level of the positive electrode is decreased to be less than or equal 94% and greater than or equal to 90% as determined via differential voltage analysis, and the fast formation protocol of the cell comprises charging the cell to the maximum charging voltage of the cell in less than 1 hour during the first formation cycle and avoiding the kinetically limited region of the positive electrode.

9 . A method for increasing battery cycle life of Li-ion battery, the method comprising:
executing a fast formation protocol on a Li-ion battery cell (cell) such that an induced Li loss shifts an electrode-specific utilization range with a lithiation level of a positive electrode of the cell decreases to be less than or equal 94% as determined via differential voltage analysis, the fast formation protocol of the cell comprising charging the cell to a maximum charging voltage of the cell in less than 1.5 hours during a first formation cycle and avoiding a kinetically limited region of the positive electrode.

10 . The method according to claim 9 , wherein the shift of the electrode-specific utilization range after formation is a decrease in the positive electrode lithiation level at full bottom discharge greater than or equal to 3% and a decrease in a negative electrode lithiation level of the cell at full cell top of charge greater than or equal to 3%, as determined via differential voltage analysis.

11 . The method according to claim 10 , wherein the shift of the electrode-specific utilization range after formation is a decrease in the positive electrode lithiation level at full bottom discharge greater than or equal to 5% and a decrease in the negative electrode lithiation level at full cell top of charge greater than or equal to 5%, as determined via differential voltage analysis.

12 . The method according to claim 11 , wherein the shift of the electrode-specific utilization range after formation is a decrease in the positive electrode lithiation level at full bottom discharge is between about 3% and about 7% and a decrease in the negative electrode lithiation level at full cell top of charge is between about 3% and about 7%, as determined via differential voltage analysis.

13 . The method according to claim 9 , wherein the fast formation protocol of the cell comprises charging the cell to the maximum charging voltage of the cell in less than 1 hour during the first formation cycle and avoiding the kinetically limited region of the positive electrode.

14 . The method according to claim 13 , wherein the shift of the electrode-specific utilization range after formation is a decrease in the positive electrode lithiation level at full bottom discharge is between about 3% and about 7% and a decrease in a negative electrode lithiation level of the cell at full cell top of charge is between about 3% and about 7%, as determined via differential voltage analysis.

15 . The method according to claim 14 , wherein the fast formation protocol of the cell comprises charging the cell to the maximum charging voltage of the cell in less than 0.5 hours during the first formation cycle and avoiding the kinetically limited region of the positive electrode.

16 . A method for increasing battery cycle life of Li-ion battery, the method comprising:
executing a fast formation protocol on a Li-ion battery cell (cell) such that an induced Li loss shifts an electrode-specific utilization range with a lithiation level of a positive electrode of the cell decreases to be less than or equal 94% as determined via differential voltage analysis, the fast formation protocol of the cell comprising charging the cell to a maximum charging voltage of the cell in less than 1.5 hours during a first formation cycle and avoiding a kinetically limited region of the positive electrode.

17 . The method according to claim 16 , wherein the shift of the electrode-specific utilization range after formation is a decrease in the positive electrode lithiation level at full bottom discharge greater than or equal to 3% and a decrease in a negative electrode lithiation level of the cell at full cell top of charge greater than or equal to 3%, as determined via differential voltage analysis.

18 . The method according to claim 17 , wherein the shift of the electrode-specific utilization range after formation is a decrease in the positive electrode lithiation level at full bottom discharge greater than or equal to 5% and a decrease in the negative electrode lithiation level at full cell top of charge greater than or equal to 5%, as determined via differential voltage analysis.

19 . The method according to claim 18 , wherein the shift of the electrode-specific utilization range after formation is a decrease in the positive electrode lithiation level at full bottom discharge is between about 3% and about 7% and a decrease in the negative electrode lithiation level at full cell top of charge is between about 3% and about 7%, as determined via differential voltage analysis.

20 . The method according to claim 16 , wherein the fast formation protocol of the cell comprises charging the cell to the maximum charging voltage of the cell in less than 1 hour during the first formation cycle and avoiding the kinetically limited region of the positive electrode.

Assignees

• Toyota Res Inst Inc
• Toyota Motor Co Ltd
• Univ Leland Stanford Junior
• Massachusetts Inst Technology

Inventors

• Chueh William C
• Sun Shijing
• Cui Xiao
• Wang Sunny
• Kang Stephen Dongmin
• Rose Justin
• Lian Huada
• Geslin Alexis
• Torrisi Stephen Bartholomew Joseph
• Bazant Martin Z

Classifications

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M4/0445 Primary

  Forming after manufacture of the electrode, e.g. first charge, cycling · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title