DESC:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION
(Section 10, rule 13)

A SODIUM-ION BATTERY

CRIMEN TECH PRIVATE LIMITED
A company registered under the laws of India

Crimen Tech Private Limited
TC 42/3015 (New TC), TC 17/1689 (Old TC), Poojapura,
Thiruvananthapuram, Kerala, India, 695012

The following specification particularly describes the invention and the manner in which it is to be performed.

A SODIUM-ION BATTERY
FIELD
The present disclosure relates generally to the energy storage devices. More particularly the present disclosure relates to sodium-ion batteries having a high power density without compromising on the energy density.
BACKGROUND
Sodium-ion batteries are well-known for their usage in cold environments with temperatures below 0 degrees Celsius. They are also relatively easy to manufacture and cost-efficient due to the abundant availability of sodium. However, sodium-ion batteries face the drawback of low power density, especially as energy densities increase.
In a sodium-ion battery, the electrode architecture typically comprises anode and cathode layers separated by an electrolyte. The electrolyte contains sodium ions, which migrate between the anode and cathode through the electrolyte during charge and discharge cycles. Current collectors may be used at each of the anode and the cathode to collect and conduct current to an appropriate point within the battery. These current collectors are usually made of conductive materials such as transition metals and are often provided as foils placed over and in electrical contact with the electrodes.
The anode may, for example, consist of a layer of alkali metal. During battery charging, alkali metal ions from the electrolyte are intercalated into the anode material, increasing the anode's volume. However, alkali metals are highly reactive and difficult to handle, making the manufacturing of electrodes containing alkali metals hazardous, complex, and costly.
It would be desirable to produce a sodium-ion battery with optimized electrode architecture that avoids the problems associated with existing designs. Most sodium-ion batteries do not exhibit high energy density, high power density, and good cycle performance simultaneously.
For instance, CN201510011674A discloses a method aimed at improving the energy density of lithium-ion batteries by increasing the thickness of both the anode and cathode. While this approach enhances energy density, it compromises power density. Similarly, non-patent literature, such as the MDPI Journal article titled “Strategies and Challenges of Thick Electrodes for Energy Storage: A Review” (Vol. 9, Issue 3), states that thicker electrodes improve energy density while thinner electrodes enhance power density. However, thick electrodes are limited by weak mechanical stability and poor electrochemical performance.
There is a need for an improved sodium-ion battery that can achieve enhanced power density without compromising energy density or cycle life. This requires the design of optimized electrode architectures that balance these critical performance parameters while addressing the limitations of conventional approaches.
OBJECT OF THE INVENTION
The primary object of the present invention is to enhance the power capability of a sodium-ion battery by optimizing the thickness ratio between the anode and cathode electrodes through the use of diverse material deposits with specific capacities.
Another object of the present invention is to carefully select active materials that contribute to increased conductivity and energy density, ensuring high power performance without compromising on the overall energy density of the battery. The invention focuses on fine-tuning the electrode structure to improve both power delivery and cycle life while maintaining a high energy density, making it suitable for applications requiring high-performance batteries with long-lasting energy storage capabilities.
An additional object of the invention is to provide an electrode fabrication method that allows for uniform coating on conductive foils, ensuring optimal porosity, consistent thickness, and reliable performance in high-power applications such as electric vehicles, air mobility systems, and power tools.
By achieving these objectives, the invention aims to address the dual challenges of maximizing energy storage and optimizing power delivery for next-generation sodium-ion cells.
SUMMARY
The following summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, example embodiments, and features described, further aspects, example embodiments, and features, will become apparent by reference to the drawings and the following detailed description.
According to an embodiment of the invention, a sodium-ion battery includes a cathode comprising a positive electroactive material that has an oxide layer selected from various materials such as O3/P2-type sodium nickel-manganese-magnesium-titanium oxide (NaaNi1?????zMnxMgyTizO2), sodium-iron-manganese-copper-based oxides, phosphates, fluoro-phosphates, Prussian Blue analogs, Prussian White, or sulfates. This material is coated onto a cathode foil, where the positive electroactive material has a specific capacity ranging from 160 to 200 mAh/g. The battery further comprises an anode made of a negative electroactive material that can be selected from hard carbon, Anthracite-based carbon, alloy-based materials, Prussian Blue analogs, non-metallic materials, or oxides, coated on an anode foil, with a specific capacity ranging from 260 to 300 mAh/g. The electrolyte solution contains organic solvents and sodium salts such as Sodium Hexafluorophosphate (NaPF6), Sodium Perchlorate (NaClO4), or Sodium Bis(trifluoromethanesulfonyl)imide (NaTFSi), along with additional additives, forming a binary or ternary mixture in specific proportions. A separator is placed between the cathode and anode to prevent direct contact, ensuring safe operation. The thickness of the cathode and anode is specifically adjusted to predefined ratios to optimize the energy and power densities of the battery.
Further, the sodium-ion battery can include various dimensions for the cathode, with a width ranging from 6.1 cm to 6.3 cm and a length from 104 cm to 124 cm. The cathode foil, acting as a current collector, is made of aluminium and has a thickness between 10 to 20 micrometres, with a surface density of 3.3 mg/cm². The positive electroactive material on the cathode is loaded in a mass range of 5 to 12 mg/cm², constituting 94% of the cathode, and has a compaction density of 2 to 2.5 g/cm³. The cathode may also include additional materials such as sodium manganese oxide (NaMnO2), sodium iron manganese oxide, sodium nickel manganese iron oxide, sodium iron phosphate, and others.
The anode may also feature additional materials for improved conductivity and energy density, such as Prussian White or Na-Fe-Mn-Cu-based oxides. The dimensions of the anode are typically between 6.2 cm to 6.4 cm in width and 110 cm to 130 cm in length. The anode foil comprises copper with a thickness ranging from 10 to 20 micrometres and a surface density of 4.22 mg/cm². The negative electroactive material on the anode has a mass loading of 10 to 15 mg/cm², constituting 92% of the anode, with a compaction density of 2 to 2.5 g/cm³.
The electrolyte solution can further include additives like vinylene carbonate (VC), which may be present in a proportion of 2 wt.% to enhance stability and extend cycle life. Specific examples of the electrolyte include 1 M sodium perchlorate (NaClO4) in EC/DEC (1:1 v/v%) with 10 wt.% fluoroethylene carbonate (FEC).
In terms of thickness, the cathode's total thickness (AT1+BT2) is adjusted to range from 135 to 137 µm, with the first side of the cathode (AT1) having a thickness of 80 µm and the second side (BT2) ranging from 55 to 57 µm. The anode's total thickness (CT3+DT4) is 140 µm, with the first side (DT4) of the anode ranging from 84 to 85 µm and the second side (CT3) between 56 to 60 µm. The first predefined ratio (AT1:DT4) is set to range from 0.9412 to 0.9523, while the second predefined ratio (BT2:CT3) ranges from 0.95 to 0.9821.
The sodium-ion battery is characterized by an initial energy density of up to 150 Wh/kg, measured when the battery is discharged within a voltage range of 2.0 to 4.0 volts. This energy density highlights the battery's ability to store and deliver substantial energy relative to its weight, making it suitable for energy-intensive applications. The battery further exhibits a capacity of up to 3.0 ampere-hours, which defines the total charge it can store and release over its operating life. Additionally, the sodium-ion battery demonstrates a cycle life of 350 cycles when subjected to a discharge rate of 1C, meaning it can be charged and discharged at its full capacity (3.0 amps for a 3.0 Ah battery) 350 times while maintaining its performance characteristics. The design is optimized for a 21700 cylindrical cell form factor, a standard widely adopted for its compatibility with applications requiring high energy density and compact size, such as electric vehicles and stationary energy storage systems.
Additionally, embodiments of the invention provide for the cathode and anode as separate components. The cathode, coated with the positive electroactive material, is designed to achieve a thickness ranging from 135 to 137 µm, with specific dimensions and mass loading for optimized performance. The anode, similarly, features a coating of the negative electroactive material, with precise thickness and mass loading to maximize its capacity and efficiency. When paired together in a sodium-ion battery, the combination of these cathode and anode elements delivers high energy and power density, making the battery suitable for various applications.
These and other embodiments of the present disclosure are discussed in further detail hereinbelow.
BRIEF DESCRIPTION OF THE FIGURES
These and other features, aspects, and advantages of the example embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
FIG. 1 illustrates a block diagram of a sodium-ion battery, according to an example embodiment;
FIG. 2 illustrates a perspective view of a cathode configured for the sodium-ion battery of FIG. 1, according to an example embodiment; and
FIG. 3 illustrates a perspective view of an anode configured for the sodium-ion battery of FIG. 1, according to an example embodiment.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
The drawings are to be regarded as being schematic representations and elements illustrated in the drawings are not necessarily shown to scale. Rather, the various elements are represented such that their function and general purpose become apparent to a person skilled in the art. Any connection or coupling between functional blocks, devices, components, or other physical or functional units shown in the drawings or described herein may also be implemented by an indirect connection or coupling. A coupling between components may also be established over a wireless connection. Functional blocks may be implemented in hardware, firmware, software, or a combination thereof.
Various example embodiments will now be described more fully with reference to the accompanying drawings in which only some example embodiments are shown. Specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Example embodiments, however, may be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.
Accordingly, while example embodiments are capable of various modifications and alternative forms, example embodiments are shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit example embodiments to the particular forms disclosed. On the contrary, example embodiments are to cover all modifications, equivalents, and alternatives thereof. Similarly, like numbers refer to like elements throughout the description of the figures.
Before discussing example embodiments in more detail, it is noted that some example embodiments are described as processes or methods depicted as flowcharts. Although the flowcharts describe the operations as sequential processes, many of the operations may be performed in parallel, concurrently or simultaneously. In addition, the order of operations may be re-arranged. The processes may be terminated when their operations are completed but may also have additional steps not included in the figure. The processes may correspond to methods, functions, procedures, subroutines, subprograms, etc.
Specific structural and functional details disclosed herein are merely representative for purposes of describing example embodiments. Inventive concepts may, however, be embodied in many alternate forms and should not be construed as limited to only the example embodiments set forth herein.
It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term "and/or" includes any, and all combinations of one or more of the associated listed items. The phrase "at least one of" has the same meaning as "and/or".
Further, although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, it should be understood that these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are used only to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed below could be termed a second element, component, region, layer, or section without departing from the scope of inventive concepts.
Spatial and functional relationships between elements (for example, between modules) are described using various terms, including “connected,” “engaged,” “interfaced,” and “coupled.” Unless explicitly described as being “direct,” when a relationship between first and second elements is described in the above disclosure, that relationship encompasses a direct relationship where no other intervening elements are present between the first and second elements, and also an indirect relationship where one or more intervening elements are present (either spatially or functionally) between the first and second elements. In contrast, when an element is referred to as being "directly” connected, engaged, interfaced, or coupled to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted in a fashion (e.g., "between," versus "directly between," "adjacent," versus "directly adjacent," etc.).
The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the," are intended to include the plural forms as well, unless the context clearly indicates otherwise. As used herein, the terms “and/or” and “at least one of” include any and all combinations of one or more of the associated listed items. It will be further understood that the terms "comprises," "comprising," "includes," and/or "including," when used herein, specify the presence of stated features, integers, steps, operations, elements, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, elements, components, and/or groups thereof.
It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may in fact be executed substantially concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skills in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper”, and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in ‘addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below”, or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, term such as “below” may encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein are interpreted accordingly.
FIG. 1 illustrates a schematic view 100 of a sodium-ion battery 102, according to an example embodiment. As shown the sodium-ion battery 102 includes a cathode 104, an anode 106, a separator 116, and an electrolyte solution 114. The sodium-ion battery is connected to an external load 124, that it powers with electrochemical process.
As shown, the cathode 104 has a cathode foil 110. On a first side 110a of the cathode foil 110 and a second side 110b of the cathode foil 110, a cathode layer 108 is deposited. The cathode layer 108 comprises of a positive electroactive material. The positive electroactive material includes an oxide layer is selected from O3/P2-type sodium nickel-manganese-magnesium-titanium oxide (NaaNi1?????zMnxMgyTizO2), odium-iron-manganese-copper-based (Na-Fe-Mn-Cu-based) oxides, phosphates, fluoro-phosphates, Prussian Blue analogs, Prussian White, or sulfates. The cathode layer 108 further comprises additional cathode materials selected from sodium manganese oxide (NaMnO2), sodium iron manganese oxide (Na[Fe1/2Mn1/2]O2), sodium nickel manganese iron oxide (Na[Ni1/3Mn1/3Fe1/3]O2), sodium iron phosphate (NaFePO4), sodium vanadium phosphate (Na3V2(PO4)3), sodium vanadium fluoro-phosphate (NaVPO4F), sodium metal ferrocyanide hydrate (Na2M[Fe(CN)6]·xH2O), sodium iron sulfate (Na2Fe2(SO4)3), and combinations thereof. The positive electroactive material is loaded onto the current collector 110 with a mass ranging from 5 to 12 mg/cm², preferably 7.8 mg/cm². Further, the positive electroactive material constitutes 94% of the cathode layer 104. The cathode layer has a compaction density ranging from 2 to 2.5 g/cm³.
Typically, the cathode foil 110 functions as a current collector and comprises of an aluminum foil. A thickness of the cathode foil 110 ranges from 10 to 20 micrometers (µm). A surface density of the cathode foil 110 is preferred at 3.3 mg/cm². As shown, the second side 110b of the cathode 104, is in touch with the electrolyte solution 114. The electrolyte solution includes organic solvents, a sodium salt selected from Sodium Hexafluorophosphate (NaPF6), Sodium Perchlorate (NaClO4), or Sodium Bis(trifluoromethanesulfonyl)imide (NaTFSi), and one or more additives, wherein the solvents are in binary or ternary mixtures in a ratio ranging from 1:1 v/v% to 1:1:3 v/v%. The electrolyte solution further includes additives such as vinylene carbonate (VC) in proportions ranging from 1 to 10 wt.%, and wherein vinylene carbonate (VC) is present in the electrolyte in a proportion of 2 wt.% to improve stability and cycle life. In an embodiment, the electrolyte solution is 1 M sodium perchlorate (NaClO4) in EC/DEC (1:1 v/v%) with 10 wt.% fluoroethylene carbonate (FEC). The separator 116 is positioned between the cathode 104 and the anode 106 to prevent direct contact. The electrolyte solution 114 flows through the separator 116.
Further, the anode 106 has an anode foil 120. On a first side 120a of the anode foil 120 and a second side 120b of the cathode foil 120, an anode layer 118 is deposited. The anode layer 118 comprises of a negative electroactive material. The negative electroactive material includes carbon, Anthracite-based carbon, alloy-based materials, Prussian Blue analogs, non-metallic materials, or oxides. Typically, the negative electroactive material has a specific capacity of 260 to 300 mAh/g. The anode foil 120 comprises a copper foil having a thickness ranging between 10 µm and 20 µm, preferably 16 µm, and a surface density of 4.22 mg/cm². Further, details of the anode and the cathode are described with respect to FIG. 2 and FIG. 3 below.
FIG. 2 illustrates a perspective view 200 of a cathode 104 configured for the sodium-ion battery 102 of FIG. 1, according to an example embodiment. As shown, a thickness (AT1) of the cathode layer 108 on the first side 110a of the cathode foil 110 is 80 µm. Further, a thickness (BT2) of the cathode layer 108 on the second side 110b of the cathode foil 110 ranges from 55 to 57 µm. Accordingly, a thickness (AT1+BT2) of the cathode 104 ranges from 135 to 137 µm. Further, as shown, the cathode 104, has dimensions of width 202 ranging from 6.1 cms to 6.3 cms, and dimensions of length 204 ranging from 104 cms to 124cms. Further, the cathode foil 110 has a thickness ranging from 10 to 20 µm. A surface density chosen for the cathode foil 110 is 3.3 mg/cm². Typically, an aluminum foil is used for the cathode foil 110. Overall, the positive electrode material used in the cathode layer 108 has a specific capacity from 160 to 200 mAh/g.
FIG. 3 illustrates a perspective view 300 of an anode 106 configured for the sodium-ion battery 102 of FIG. 1, according to an example embodiment. As shown, a thickness (DT4) of the anode layer 118 on the first side 120a of the anode foil 120 ranges from 84 to 85 µm. Further, a thickness (CT3) of the anode layer 118 on the second side 110b of the anode foil 120 ranges from 56 to 60µm. Accordingly, a thickness (CT3+DT4) of the anode 106 ranges from 140 to 145µm. Further, as shown, the anode 106, has dimensions of width 302 ranging from 6.2 cms to 6.4 cms, and dimensions of length 304 ranging from 110 cms to 130 cms.
Further, the anode foil 120 has a thickness ranging from 10 to 20 µm. A preferrable thickness of the anode foil is 16 µm . A surface density chosen for the anode foil 120 is 4.22 mg/cm². Typically, a copper foil is used for the anode foil 1200. Overall, the negative electrode material used in the anode layer 118 has a specific capacity from 160 to 200 mAh/g. The negative electroactive material on the anode foil has a mass loading ranging from 10 to 15 mg/cm², preferably 12.6 mg/cm². The negative electroactive material comprises 92% of the anode's composition and exhibits a compaction density between 2 and 2.5 g/cm³. The negative electroactive material exhibits a specific capacity ranging from 260 to 300 mAh/g. The anode layer 118 includes additional materials such as Prussian White, Na-Fe-Mn-Cu-based oxides, or alloy-based materials, enhancing both conductivity and energy density.
In an embodiment, the first predefined ratio (AT1:DT4) ranges from 0.9412 to 0.9523, while the second predefined ratio (BT2:CT3) ranges from 0.95 to 0.9821. The sodium-ion battery 102 achieves an energy density of up to 110 Wh/kg. Fine-tuning the thickness ratios within a sodium-ion battery plays a crucial role in enhancing energy density while maintaining power density. In one embodiment, the first predefined ratio (AT1:DT4) is optimized to range between 0.9412 and 0.9523, while the second predefined ratio (BT2:CT3) is adjusted to fall between 0.95 and 0.9821. This precise calibration allows the sodium-ion battery to achieve an energy density of up to 110 Wh/kg, striking an effective balance between energy storage capacity and power output.
The thickness ratios of the anode and cathode layers significantly influence the battery's energy density, power density, and overall efficiency. Energy density, which represents the amount of energy stored per unit weight (Wh/kg), is primarily determined by the cathode, where positive ions are stored during the discharge cycle. Optimizing the thickness ratio of the cathode (AT1 and BT2) relative to the anode (CT3 and DT4) enhances the balance of electrochemical reactions. A thicker cathode layer increases active material loading, thereby boosting energy storage capacity. However, excessive cathode thickness can lead to inefficient ion diffusion and increased resistance, limiting the battery’s charge and discharge rates.
Power density, defined as the rate at which the battery can deliver energy (W/kg), is directly affected by the mobility of ions between the anode and cathode. Adjusting thickness ratios ensures optimal diffusion pathways for sodium ions, minimizing resistance and enhancing ion transport. Balanced thickness ratios prevent overloading of either electrode, mitigating polarization effects and maintaining consistent power output. The first predefined ratio (AT1:DT4) regulates the relationship between the first cathode layer (AT1) and the second anode layer (DT4), optimizing energy density without compromising structural integrity or significantly increasing resistance. Similarly, the second predefined ratio (BT2:CT3) fine-tunes the relationship between the second cathode layer (BT2) and the first anode layer (CT3), ensuring efficient ion transport and avoiding bottlenecks during high-rate charge and discharge cycles.
The trade-offs between energy density and power density are also closely tied to electrode thickness. Thicker electrodes generally enhance energy density due to greater active material content but can increase internal resistance, reducing power density. Conversely, thinner electrodes improve power density by shortening ion diffusion pathways but decrease energy density as the amount of active material is reduced. Proper calibration of thickness ratios addresses these trade-offs, ensuring an ideal balance.
Beyond electrochemical performance, adjusting thickness ratios also enhances the battery’s thermal and mechanical stability. Uniform current distribution, enabled by balanced thickness ratios, reduces the risk of overheating and degradation over repeated charge-discharge cycles. This improves the battery’s thermal management and prolongs its operational lifespan.
In practical terms, fine-tuning the ratios—such as maintaining AT1:DT4 between 0.9412 and 0.9523 and BT2:CT3 between 0.95 and 0.9821—ensures that the sodium-ion battery achieves a high energy density of up to 110 Wh/kg while retaining robust power density. These characteristics make the battery suitable for demanding applications such as electric vehicles and grid storage systems, which require both substantial energy storage and rapid discharge capabilities. By achieving an optimal balance between the anode and cathode layer thicknesses, the battery maximizes electrochemical efficiency, extends cycle life, and delivers superior overall performance.
It will be understood by those within the art that, in general, terms used herein, are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present.
For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to embodiments containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., “a” and/or “an” should be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations).
While only certain features of several embodiments have been illustrated, and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of inventive concepts.
The aforementioned description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure may be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification. It should be understood that one or more steps within a method may be executed in a different order (or concurrently) without altering the principles of the present disclosure. Further, although each of the example embodiments is described above as having certain features, any one or more of those features described with respect to any example embodiment of the disclosure may be implemented in and/or combined with features of any of the other embodiments, even if that combination is not explicitly described. In other words, the example embodiments described are not mutually exclusive, and permutations of one or more example embodiments with one another remain within the scope of this disclosure.
The example embodiment or each example embodiment should not be understood as a limiting/restrictive of inventive concepts. Rather, numerous variations and modifications are possible in the context of the present disclosure, in particular those variants and combinations which may be inferred by the person skilled in the art with regard to achieving the object for example by combination or modification of individual features or elements or method steps that are described in connection with the general or specific part of the description and/or the drawings, and, by way of combinable features, lead to a new subject matter or to new method steps or sequences of method steps, including insofar as they concern production, testing and operating methods. Further, elements and/or features of different example embodiments may be combined with each other and/or substituted for each other within the scope of this disclosure.

,CLAIMS:We Claim:
1. A sodium-ion battery comprising:
a cathode having a cathode layer comprising positive electroactive material with an oxide layer selected from O3/P2-type sodium nickel-manganese-magnesium-titanium oxide (NaaNi1?????zMnxMgyTizO2), sodium-iron-manganese-copper-based (Na-Fe-Mn-Cu-based) oxides, phosphates, fluoro-phosphates, Prussian Blue analogs, Prussian White, or sulfates, wherein the positive electroactive material has a specific capacity of 160 to 200 mAh/g;
an anode having an anode layer comprising a negative electroactive material selected from hard carbon, Anthracite-based carbon, alloy-based materials, Prussian Blue analogs, non-metallic materials, or oxides, wherein the negative electroactive material has a specific capacity of 260 to 300 mAh/g;
an electrolyte solution comprising organic solvents, a sodium salt selected from Sodium Hexafluorophosphate (NaPF6), Sodium Perchlorate (NaClO4), or Sodium Bis(trifluoromethanesulfonyl)imide (NaTFSi), and one or more additives, wherein the solvents are in binary or ternary mixtures in a ratio ranging from 1:1 v/v% to 1:1:3 v/v%;
a separator positioned between the cathode and anode to prevent direct contact;
wherein a thickness (AT1) of a first side of the cathode and a thickness (DT4) of a second side of the anode are adjusted to a first predefined ratio to increase energy density, and
wherein a thickness (BT2) of a second side of the cathode and a thickness (CT3) of a first side of the anode are adjusted to a second predefined ratio to increase a power density of the sodium-ion battery.
2. The sodium-ion battery of claim 1, wherein the cathode has dimensions ranging from 6.1 cm to 6.3 cm in width and 104 cm to 124 cm in length.

3. The sodium-ion battery of claim 1, wherein the cathode foil functions as a current collector and comprises of an aluminum foil with a thickness ranging from 10 to 20 micrometers (µm) and a surface density of 3.3 mg/cm².
4. The sodium-ion battery of claim 1, wherein the positive electroactive material is loaded onto the current collector with a mass ranging from 5 to 12 mg/cm², preferably 7.8 mg/cm², constitutes 94% of the cathode layer, and wherein the cathode layer has a compaction density ranging from 2 to 2.5 g/cm³.
5. The sodium-ion battery of claim 1, wherein the cathode layer further comprises additional cathode materials selected from sodium manganese oxide (NaMnO2), sodium iron manganese oxide (Na[Fe1/2Mn1/2]O2), sodium nickel manganese iron oxide (Na[Ni1/3Mn1/3Fe1/3]O2), sodium iron phosphate (NaFePO4), sodium vanadium phosphate (Na3V2(PO4)3), sodium vanadium fluoro-phosphate (NaVPO4F), sodium metal ferrocyanide hydrate (Na2M[Fe(CN)6]·xH2O), sodium iron sulfate (Na2Fe2(SO4)3), and combinations thereof.
6. The sodium-ion battery of claim 1, wherein the anode layer comprises additional materials selected from Prussian White, Na-Fe-Mn-Cu based oxides, or alloy-based materials for improved conductivity and energy density.
7. The sodium-ion battery of claim 1, wherein the anode has dimensions ranging from 6.2 cm to 6.4 cm in width and 110 cm to 130 cm in length.
8. The sodium-ion battery of claim 1, wherein the anode foil comprises a copper foil having a thickness ranging between 10 µm and 20 µm, preferably 16 µm, and a surface density of 4.22 mg/cm².
9. The sodium-ion battery of claim 1, wherein a mass loading of the negative electroactive material on the anode foil is 10 to 15 mg/cm2, preferably 12.6 mg/cm², the negative electroactive material constitutes 92% of the anode, and a compaction density is in the range of 2 to 2.5 g/cm³.
10. The sodium-ion battery of claim 1, wherein the electrolyte solution further includes additives such as vinylene carbonate (VC) in proportions ranging from 1 to 10 wt.%, and wherein vinylene carbonate (VC) is present in the electrolyte in a proportion of 2 wt.% to improve stability and cycle life, wherein the electrolyte solution is 1 M sodium perchlorate (NaClO4) in EC/DEC (1:1 v/v%) with 10 wt.% fluoroethylene carbonate (FEC).
11. The sodium-ion battery of claim 1, wherein a thickness of the cathode (AT1+BT2) ranges from 135 to 137 µm, wherein a thickness of the first side (AT1) of the cathode is 80 µm and a thickness of the second side (BT2) of the cathode ranges from 55 to 57 µm.
12. The sodium-ion battery of claim 1, wherein a thickness of the anode (CT3+DT4) is 140 µm, wherein a thickness of the first side (DT4) of the anode ranges from 84 to 85 µm and a thickness of the second side (CT3) ranges from 56 to 60 µm.
13. The sodium-ion battery of claim 1, wherein the first predefined ratio (AT1:DT4) ranges from 0.9412 to 0.9523 to and wherein the second predefined ratio (BT2:CT3) ranges from 0.95 to 0 .9821.
14. The sodium ion battery of claim 1, wherein the sodium-ion battery has an initial energy density of up to 150 Wh/kg when discharged at a voltage of 2.0 to 4.0 V, and a capacity of up to 3.0 Ampere-hour with a cycle life of 350 cycles when discharges 1C for a 21700 form factor.
15. The sodium ion battery of claim 1, wherein the energy density of the sodium ion battery is up to 110 Wh/kg.
16. A cathode for use in a sodium-ion battery, the cathode comprising:
a cathode foil coated with a layer of a positive electroactive material with an oxide layer is coated, wherein the oxide layer is selected from O3/P2-type sodium nickel-manganese-magnesium-titanium oxide (NaaNi1?????zMnxMgyTizO2), odium-iron-manganese-copper-based (Na-Fe-Mn-Cu-based) oxides, phosphates, fluoro-phosphates, Prussian Blue analogs, Prussian White, or sulfates;
wherein a thickness of a first side (AT1) of the cathode is 80 µm, a thickness of a second side (BT2) of the cathode ranges from 55 to 57 µm, and a thickness of the cathode (AT1+BT2) ranges from 135 to 137 µm; and
wherein the positive electroactive material has a specific capacity from 160 to 200 milliampere-hours per gram (mAh/g).
17. The cathode of claim 16, wherein the cathode foil functions as a current collector and comprises of an aluminum foil with a thickness ranging from 10 to 20 micrometers (µm) and a surface density of 3.3 mg/cm², wherein the cathode has dimensions ranging from 6.1 cms to 6.3 cms in width and 104 cms to 124 cms in length.
18. The cathode of claim 16, wherein the positive electroactive material is loaded onto the current collector with a mass ranging from 5 to 12 mg/cm², preferably 7.8 mg/cm², constitutes 94% of the cathode, and has a compaction density in the range of 2 to 2.5 g/cm³.
19. An anode for use in a sodium-ion battery, the anode comprising:
an anode foil coated with a layer of a negative electroactive material comprising hard carbon, Anthracite-based carbon, alloy-based materials, Prussian Blue analogs, non-metallic materials, or oxides;
wherein the negative electroactive material has a specific capacity of 260 to 300 mAh/g;
wherein a thickness of the anode (CT3+DT4) ranges from 140 to 145 µm,
wherein a thickness of a first side (DT4) of the anode ranges from 84 to 85 µm and a thickness of a second side (CT3) ranges from 56 to 60 µm; and
wherein a mass loading of the negative electroactive material on the anode foil ranges from 10 to 15 mg/cm2, preferably 12.6 mg/cm², wherein the negative electroactive material constitutes 92% of the anode, and a compaction density is in the range of 2 to 2.5 g/cm³.

20. The anode of claim 19, when paired with a cathode within a sodium ion battery provides an energy density up to 110 Wh/kg , the cathode comprising:
a cathode foil coated with a layer of a positive electroactive material with an oxide layer is coated, wherein the oxide layer is selected from O3/P2-type sodium nickel-manganese-magnesium-titanium oxide (NaaNi1?????zMnxMgyTizO2), sodium-iron-manganese-copper-based (Na-Fe-Mn-Cu-based) oxides, phosphates, fluoro-phosphates, Prussian Blue analogs, Prussian White, or sulfates;
wherein a thickness of a first side (AT1) of the cathode is 80 µm, a thickness of a second side (BT2) of the cathode ranges from 55 to 57 µm, and a thickness of the cathode (AT1+BT2) ranges from 135 to 137 µm.