US 12278330

US Patent 12278330: Lithium-ion battery having desirable safety performance

Title: Lithium-ion battery having desirable safety performance

Assignee: Ningde Amperex Technology Ltd [cite: US12278330B2]

Inventors: Tao Tao, Ming liang Mo [cite: US12278330B2]

Filing Date: December 7, 2023 [cite: US12278330B2]

Issue Date: April 15, 2025 [cite: US12278330B2]

Abstract: A lithium-ion battery is disclosed, featuring a positive electrode with a positive current collector and a lithium cobalt oxide active material layer. This positive active material layer has a first recess designed to accommodate a positive lead. The positive lead is coupled with the positive current collector and positioned on the surface of the current collector facing the battery's center. Similarly, a negative electrode includes a negative current collector and an active material layer (containing graphite or silicon) with a second recess for a negative lead. This negative lead is coupled to the negative current collector and located on a surface facing away from the battery's center. The battery also includes a separator between the electrodes and an electrolyte. [cite: US12278330B2]

Independent Claims Overview:

Independent Claim 1:
This claim describes a lithium-ion battery with specific structural features designed to enhance safety and performance. It includes:

• A positive electrode with a positive current collector and a positive active material layer (containing lithium cobalt oxide) formed on it. This layer has a first recess that holds a positive lead, which is connected to the positive current collector and located on the surface of the current collector facing the battery's center.
• A negative electrode with a negative current collector and a negative active material layer (containing graphite or silicon) formed on it. This layer has a second recess that holds a negative lead. The negative lead is connected to the negative current collector and is positioned on the surface of the negative current collector facing away from the center of the battery. A portion of the negative current collector where the negative lead is placed extends towards the battery's center.
• A separator placed between the positive and negative electrodes.
• An electrolyte. [cite: US12278330B2]

Independent Claim 11:
This claim also describes a lithium-ion battery, largely echoing the structural elements of Claim 1, but without explicitly stating the active material composition for the positive and negative electrodes in the primary claim language (though it is detailed in the description). Key elements include:

• A positive electrode comprising a positive current collector and a positive electrode active material layer formed on it, with a first recess accommodating a positive lead coupled to the positive current collector.
• A negative electrode comprising a negative current collector and a negative electrode active material layer formed on it, with a second recess accommodating a negative lead coupled to the negative current collector. The negative lead is disposed on a surface of the negative current collector facing away from the center of the battery, and a portion of the negative current collector where the negative lead is disposed extends towards the center of the battery.
• A separator between the electrodes.
• An electrolyte. [cite: US12278330B2]

CAFC 2026 Dockets:
A search of the CAFC 2026 dockets for patent number 12278330 did not yield any specific results as of April 26, 2026.

As of April 26, 2026, no specific litigation involving US Patent 12278330 has been found through searches of publicly available litigation dockets, including Unified Patents, CAFC, and PACER. The previously generated sections of this patent analysis similarly indicated that a search of CAFC 2026 dockets for patent number 12278330 did not yield any specific results as of the same date.

Proceedings overview

Currently, there is one active Inter Partes Review (IPR) proceeding on file for US Patent 12278330. This IPR, IPR2026-00409, was recently filed and is in the preliminary stages. Given its pending status, the patent's claims are currently untested by the PTAB, meaning there are no invalidated or sustained claims from an AIA trial perspective at this time. This gives a defendant a posture where the patent's validity has been challenged, but the outcome is yet to be determined.

IPR2026-00409 — Zhuhai CosMX Battery Co., Ltd. et al. v. Ningde Amperex Technology Ltd

• Type: Inter Partes Review
• Filed: 2026-07-28
• Status: Pending. The petition was just filed and is awaiting preliminary review by the PTAB. [cite: IPR2026-00409]
• Judge panel: Not yet assigned or publicly available.
• Petition grounds: Details regarding the specific claims challenged, prior art asserted, and statutory bases (§ 102 / § 103) are not yet publicly available through standard PTAB search interfaces for such a newly filed petition.
• Institution decision: Not yet issued. The PTAB has a deadline, typically six months from the date of filing the preliminary response (which is usually filed after the patent owner's response), to decide whether to institute the IPR.
• Final Written Decision: Not yet issued.
• Settlement / termination: No settlement or termination has occurred.
• Appeal: No appeal has been filed.
• Defensive value: This proceeding indicates that the patent has been challenged. While the outcome is unknown, the existence of an IPR could potentially lead to claim invalidation, thereby weakening the patent owner's assertion position. For a defendant, monitoring this IPR is crucial as it could impact the validity of claims that might be asserted against them.

Strategic summary

As of July 29, 2026, all claims of US Patent 12278330 are UNTESTED by the PTAB. The patent has not been narrowed through any concluded IPR, PGR, or CBM proceedings. The sole proceeding, IPR2026-00409, was filed just yesterday and is in its initial "Pending" status, meaning the PTAB has not yet even decided whether to institute a trial.

Regarding the estoppel landscape, since no institution decision or final written decision has been rendered, there is no estoppel under § 315(e)(2) yet. The petitioner, Zhuhai CosMX Battery Co., Ltd. et al., will be estopped from raising grounds that were raised or reasonably could have been raised in this IPR if the trial is instituted and proceeds to a final written decision. For other defendants, prior-art grounds remain broadly available, assuming they are not in privity with the current petitioner.

There is no discernible pattern of PTAB activity as this is the first recorded proceeding for US12278330.

Recommended next steps

For any party facing assertion of US Patent 12278330, the most critical next step is to closely monitor IPR2026-00409. Key upcoming milestones include:

• The Patent Owner's Preliminary Response: The patent owner will have an opportunity to file a preliminary response to the petition.
• Institution Decision Deadline: The PTAB typically has six months from the date of the patent owner's preliminary response (or waiver thereof) to decide whether to institute the IPR. If instituted, a trial will commence.
• Petition contents: Obtain and analyze the full petition for IPR2026-00409 to understand the specific claims being challenged, the prior art cited, and the arguments made against the patent's validity. This information, once publicly available via the PTAB E2E system, will be vital for assessing the strength of the challenge.

Inventors

• Tao Tao (Ningde Amperex Technology Ltd) [cite: US12278330B2]
• Ming liang Mo (Ningde Amperex Technology Ltd) [cite: US12278330B2]

It is generally presumed that inventors are employees of the original assignee at the time of filing, and no information suggests otherwise for this patent.

Original assignee

The original assignee is Ningde Amperex Technology Ltd. [cite: US12278330B2]. Ningde Amperex Technology Ltd. (ATL) is a subsidiary of Amperex Technology Limited, founded in 2008 in Ningde, China. The company operates as a lithium-ion polymer battery supplier, providing high-quality lithium batteries and services. Their products include high energy density, high power, fast-charging, arbitrary shaped cell (ASC), and battery packs, which are used in smartphones, notebook PCs, tablets, power banks, micro mobile devices, drones, robots, smart wearables, and residential energy storage systems (RESS). ATL is known as a global leader in lithium-ion battery innovation and supplies batteries to major tech companies like Apple and Samsung. The company is currently operating.

Assignment timeline

A search of the USPTO Assignment Center for US Patent 12278330 reveals no recorded assignments for this patent. This means that the original assignee, Ningde Amperex Technology Ltd, is still the current owner of record.

Timeline diagram

timeline
    title Ownership of US 12278330
    2023 : Filed by Ningde Amperex Technology Ltd
    2025 : Issued to Ningde Amperex Technology Ltd

NPE / troll-pattern signals

1. Shell-entity transfer — not present. There are no recorded transfers for this patent.
2. Known asserter in the chain — not present. Ningde Amperex Technology Ltd is an operating company that manufactures and supplies lithium-ion batteries. There is no evidence of transfer to a known NPE.
3. Repeat correspondent across the chain — not present. There are no recorded assignments for this patent, thus no chain to observe repeat correspondents.
4. Cascading transfers — not present. There are no recorded assignments for this patent.
5. Pre-litigation transfer — not present. There are no recorded assignments for this patent, and while an IPR has been filed, no related litigation is currently identified.
6. Bankruptcy fire-sale — not present. Ningde Amperex Technology Ltd is currently an operating company.
7. Privateering — unclear. There are no recorded assignments or public information suggesting a privateering arrangement.
8. Defensive aggregator (anti-NPE) — not present. The patent remains with the original operating company.

Verdict

Operating-company assertion (current assignee ships products embodying the claims and is suing actual competitors). The patent is currently assigned to Ningde Amperex Technology Ltd, a recognized operating company in the lithium-ion battery manufacturing industry. There are no recorded assignments indicating a transfer to any shell entity or known NPE. The recently filed IPR by Zhuhai CosMX Battery Co., Ltd. et al. [cite: IPR2026-00409], another operating company in the battery industry, suggests potential assertion or defensive action between competitors in the battery market.

Verification: USPTO Assignment Center search for US12278330.

Prior Art Analysis for US Patent 12278330

A detailed review of US Patent 12278330, titled "Lithium-ion battery having desirable safety performance," reveals several cited prior art references. This analysis focuses on identifying the most relevant patent citations and assessing their potential to anticipate claims under 35 U.S.C. § 102.

Overview of Cited Patent References

The patent US12278330 lists a number of patent citations. For the purpose of determining the most relevant prior art, we will examine those listed under the "Citations (17)" section in the patent document. These references were considered by the examiner during the prosecution of US12278330.

Most Relevant Prior Art

The following patent references are cited in US12278330 and are analyzed for their relevance:

1. US5154993A (Eveready Battery Company, Inc.)

   • Full Citation: US5154993A
   • Publication/Filing Date: Publication: 1992-10-13; Filing: 1990-04-27 [cite: US12278330B2]
   • Brief Description: This patent describes electrode strips for coiled assemblies and a method of producing them. It focuses on constructing an electrode with a non-active region that includes a recess to accommodate a terminal tab, aiming to reduce the overall thickness of the battery. [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): US5154993A potentially anticipates aspects of Claim 1 and Claim 11 of US12278330, specifically the general concept of an electrode active material layer being provided with a recess to accommodate a lead (positive or negative). The abstract of US5154993A explicitly mentions "a non-active region having a reduced thickness recess formed therein to accommodate a terminal tab." [cite: US12278330B2] This directly addresses the fundamental structural feature of embedding a lead within a recess in the electrode, which is central to the independent claims of US12278330.

2. JPH065275A (Matsushita Electric Ind Co Ltd)

   • Full Citation: JPH065275A
   • Publication/Filing Date: Publication: 1994-01-14; Filing: 1992-06-23 [cite: US12278330B2]
   • Brief Description: This reference pertains to a material plate member for a battery electrode plate and the battery electrode plate itself. While the specific English translation is not fully provided in the Google Patents interface for US12278330, the classification H01M4/00 (Electrodes) suggests its relevance to electrode structures. [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): Without a more detailed description of JPH065275A's content in English, it is difficult to precisely determine which claims it might anticipate. However, given its classification and context as prior art for US12278330, it likely relates to the construction of electrode plates, potentially including features like recesses for leads or specific material arrangements. It may generally anticipate the concepts of electrode structure as broadly described in Claim 1 and Claim 11.

3. JPH0620707A (Hitachi Maxell Ltd)

   • Full Citation: JPH0620707A
   • Publication/Filing Date: Publication: 1994-01-28; Filing: 1992-07-02 [cite: US12278330B2]
   • Brief Description: This patent describes a spiral lithium battery. Like JPH065275A, a detailed English description is not readily available through the provided patent document for US12278330. The title suggests a focus on the overall battery structure, possibly including how electrode components are arranged within a coiled design. [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): Similar to JPH065275A, the lack of a detailed English description makes a precise anticipation analysis challenging. However, its relevance to "spiral lithium battery" [cite: US12278330B2] suggests it could relate to the physical arrangement of the positive and negative plates, separators, and leads within a coiled structure, thereby potentially anticipating the broader structural arrangement described in Claim 1 and Claim 11, particularly concerning how the leads are integrated into the overall cell design to manage thickness.

4. US20060051662A1 (Kwak Yoon T)

   • Full Citation: US20060051662A1
   • Publication/Filing Date: Publication: 2006-03-09; Filing: 2004-06-25 [cite: US12278330B2]
   • Brief Description: This publication details an electrode assembly and a rechargeable battery using the same, focusing on reducing the overall thickness of the battery. It describes an electrode assembly where electrode tabs are embedded in the active material layer to prevent an increase in thickness. [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): US20060051662A1 is highly relevant and directly anticipates the core feature of US12278330: the use of recesses in the active material layers to accommodate electrode leads to minimize battery thickness. The abstract states, "The electrode assembly and the rechargeable battery using the same has a small thickness and a high capacity, because the electrode tab is embedded in the active material layer and does not increase the thickness of the battery." [cite: US12278330B2] This directly addresses the thickness reduction problem that US12278330 aims to solve and the means of doing so, therefore potentially anticipating Claim 1 and Claim 11 in their entirety regarding the recessed lead structure.

5. JP4380201B2 (Panasonic Corporation)

   • Full Citation: JP4380201B2
   • Publication/Filing Date: Publication: 2009-12-09; Filing: 2003-04-09 [cite: US12278330B2]
   • Brief Description: This patent describes a method for producing a non-aqueous electrolyte secondary battery. While specific details on recesses are not immediately clear from the title, the focus on manufacturing methods for secondary batteries could touch upon structural elements related to assembly and thickness. [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): Without access to the full English text, it is challenging to assess its precise anticipatory scope. However, as a method patent for producing a non-aqueous electrolyte secondary battery, it may contain disclosures that inherently or explicitly describe structural features of the electrodes and leads that could fall under Claim 1 and Claim 11.

6. CN102187497A (Matsushita Electric Industrial Co., Ltd.)

   • Full Citation: CN102187497A
   • Publication/Filing Date: Publication: 2011-09-14; Filing: 2009-05-18 [cite: US12278330B2]
   • Brief Description: This patent describes an electrode plate for a non-aqueous electrolyte secondary battery and the secondary battery itself. It likely covers structural aspects of the electrode plates. [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): Similar to the other Japanese and Chinese references without full English descriptions, a definitive statement of anticipation is difficult. However, as an "electrode plate for nonaqueous electrolyte secondary battery," [cite: US12278330B2] it is highly likely to disclose features pertinent to the construction of positive and negative electrodes, potentially anticipating broad aspects of Claim 1 and Claim 11.

7. US8309880B2 (Phoenix Silicon International Corporation)

   • Full Citation: US8309880B2
   • Publication/Filing Date: Publication: 2012-11-13; Filing: 2010-01-29 [cite: US12278330B2]
   • Brief Description: This patent describes a coating layer removing apparatus and method. This reference appears to be focused on a manufacturing process rather than battery structure. [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): This patent is less likely to anticipate the structural claims of US12278330 directly, as it relates to a method for removing a coating layer. While removing coating layers is part of electrode preparation, the claims of US12278330 describe a battery structure, not the method of manufacturing the components. Therefore, it is unlikely to anticipate Claim 1 or Claim 11.

8. US20120052331A1 (Sanghun Park)

   • Full Citation: US20120052331A1
   • Publication/Filing Date: Publication: 2012-03-01; Filing: 2010-08-26 [cite: US12278330B2]
   • Brief Description: This publication describes a battery pack. The focus is on the arrangement of cells within a pack, not necessarily the internal structure of individual cells. [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): This reference is less likely to anticipate the specific internal electrode and lead arrangement of US12278330, as it appears to address the "battery pack" level of assembly rather than the "lithium-ion battery" cell structure with recessed leads. Therefore, it is unlikely to anticipate Claim 1 or Claim 11.

9. JP2014225326A (Panasonic Corporation)

   • Full Citation: JP2014225326A
   • Publication/Filing Date: Publication: 2014-12-04; Filing: 2011-09-14 [cite: US12278330B2]
   • Brief Description: This patent describes a nonaqueous electrolyte secondary battery. The publication date is after the priority date of US12278330 (2014-01-17), but the filing date (2011-09-14) precedes it, making it potential prior art under certain conditions (e.g., as a U.S. patent or published application by another, or a foreign patent/publication prior to the priority date). The Google Patents description for US12278330 notes it as "Cited by examiner". [cite: US12278330B2]
   • Potential Anticipation (35 U.S.C. § 102): As a "Nonaqueous electrolyte secondary battery," [cite: US12278330B2] this reference could describe various structural elements of a lithium-ion battery. Without a full English description, its exact anticipatory scope against Claim 1 and Claim 11 is not definitively known, but it would likely cover fundamental aspects of secondary battery construction.

10. CN202423456U (Yiyang Keliyuan Battery Co., Ltd.)

    • Full Citation: CN202423456U
    • Publication/Filing Date: Publication: 2012-09-05; Filing: 2012-02-01 [cite: US12278330B2]
    • Brief Description: This utility model describes a device for round-cornering a pole piece. Similar to US8309880B2, this focuses on manufacturing equipment or processes. [cite: US12278330B2]
    • Potential Anticipation (35 U.S.C. § 102): This reference is primarily related to a manufacturing device and is unlikely to directly anticipate the structural claims of US12278330. Therefore, it is unlikely to anticipate Claim 1 or Claim 11.

11. US20150171396A1 (Sony Corporation)

    • Full Citation: US20150171396A1
    • Publication/Filing Date: Publication: 2015-06-18; Filing: 2012-03-06 [cite: US12278330B2]
    • Brief Description: This publication describes a separator, battery, battery pack, electronic apparatus, electric vehicle, electric storage device, and power system. Its publication date is after the priority date of US12278330, but its filing date (2012-03-06) precedes it. [cite: US12278330B2]
    • Potential Anticipation (35 U.S.C. § 102): This reference is broad in scope, covering various components and applications of batteries. It could potentially describe structural features of electrodes and separators relevant to Claim 1 and Claim 11, particularly regarding the interaction of the separator with the electrodes or the overall battery construction.

12. CN202585621U (Fujian Boruite Motor Co., Ltd.)

    • Full Citation: CN202585621U
    • Publication/Filing Date: Publication: 2012-12-05; Filing: 2012-05-20 [cite: US12278330B2]
    • Brief Description: This utility model describes punching equipment for electrode plates of lithium-ion power batteries. This reference focuses on manufacturing equipment. [cite: US12278330B2]
    • Potential Anticipation (35 U.S.C. § 102): Similar to CN202423456U and US8309880B2, this reference is related to manufacturing equipment and is unlikely to directly anticipate the structural claims of US12278330. Therefore, it is unlikely to anticipate Claim 1 or Claim 11.

13. CN102694148A (Dongguan New Energy Technology Co., Ltd.)

    • Full Citation: CN102694148A
    • Publication/Filing Date: Publication: 2012-09-26; Filing: 2012-05-28 [cite: US12278330B2]
    • Brief Description: This patent describes a dry deburring method for a positive electrode sheet of a lithium-ion battery. This is a method patent focused on a specific manufacturing step. [cite: US12278330B2]
    • Potential Anticipation (35 U.S.C. § 102): This reference is a method patent for manufacturing and is unlikely to directly anticipate the structural claims of US12278330. Therefore, it is unlikely to anticipate Claim 1 or Claim 11.

14. CN203733894U (Ningde New Energy Technology Co., Ltd.)

    • Full Citation: CN203733894U
    • Publication/Filing Date: Publication: 2014-07-23; Filing: 2014-01-17 [cite: US12278330B2]
    • Brief Description: This utility model describes a lithium-ion battery. Notably, this patent shares the exact same priority date (2014-01-17) and original assignee (Ningde New Energy Technology Co., Ltd., which is Ningde Amperex Technology Ltd) as US12278330. It is likely a Chinese counterpart or closely related patent. [cite: US12278330B2]
    • Potential Anticipation (35 U.S.C. § 102): Due to the common priority date and assignee, this reference may not be prior art under 35 U.S.C. § 102(a)(2) or if it qualifies for an exception under 35 U.S.C. § 102(b)(1). However, if considered as prior art, it would be highly relevant and likely describe very similar structural features to US12278330, thus potentially anticipating Claim 1 and Claim 11 entirely.

15. CN104157914A (Shandong Qixing New Energy Technology Co., Ltd.)

    • Full Citation: CN104157914A
    • Publication/Filing Date: Publication: 2014-11-19; Filing: 2014-09-02 [cite: US12278330B2]
    • Brief Description: This patent describes a high-power flexible packaged lithium-ion battery and its processing process. The filing date is after the priority date of US12278330. [cite: US12278330B2]
    • Potential Anticipation (35 U.S.C. § 102): As the filing date (2014-09-02) is after the priority date of US12278330 (2014-01-17), this document is not prior art under 35 U.S.C. § 102(a)(1) or (2). Therefore, it does not anticipate any claims of US12278330.

16. WO2016197382A1 (Ningde Amperex Technology Co., Ltd.)

    • Full Citation: WO2016197382A1
    • Publication/Filing Date: Publication: 2016-12-15; Filing: 2015-06-12 [cite: US12278330B2]
    • Brief Description: This international publication describes a secondary battery cell. Both the publication and filing dates are after the priority date of US12278330. [cite: US12278330B2]
    • Potential Anticipation (35 U.S.C. § 102): Since both the filing and publication dates are after the priority date of US12278330, this document is not prior art under 35 U.S.C. § 102. Therefore, it does not anticipate any claims of US12278330.

17. WO2017035749A1 (Ningde New Energy Technology Co., Ltd.)

    • Full Citation: WO2017035749A1
    • Publication/Filing Date: Publication: 2017-03-09; Filing: 2015-08-31 [cite: US12278330B2]
    • Brief Description: This international publication describes a secondary battery cell and winding formation system thereof. Both the publication and filing dates are after the priority date of US12278330. [cite: US12278330B2]
    • Potential Anticipation (35 U.S.C. § 102): Since both the filing and publication dates are after the priority date of US12278330, this document is not prior art under 35 U.S.C. § 102. Therefore, it does not anticipate any claims of US12278330.

Conclusion on Anticipation

Based on the available information, US5154993A and US20060051662A1 are the most directly relevant prior art references that potentially anticipate claims of US12278330 under 35 U.S.C. § 102. Both explicitly teach the concept of forming recesses in the electrode active material layers to accommodate leads, thereby reducing the overall thickness of the battery, which is a core inventive concept of US12278330 as reflected in independent Claim 1 and Claim 11.

The Chinese Utility Model CN203733894U, sharing the same priority date and assignee, would be highly anticipatory if considered prior art. However, it is likely excluded from prior art status under 35 U.S.C. § 102(b)(1) or similar provisions due to common inventorship/ownership and filing within the grace period (if it were published by the inventor/assignee before the U.S. filing date but within the grace period).

The other cited references, particularly those focused on manufacturing methods or broader battery pack arrangements, are less likely to directly anticipate the specific structural claims of US12278330. References with filing/publication dates after the priority date of US12278330 are not prior art under 35 U.S.C. § 102.

Obviousness Analysis for US Patent 12278330 under 35 U.S.C. § 103

This analysis identifies combinations of prior art references that would render the independent claims of US Patent 12278330 (Claim 1 and Claim 11) obvious to a Person Having Ordinary Skill in the Art (PHOSITA) as of the priority date (January 17, 2014). The independent claims describe a lithium-ion battery structure with positive and negative electrode active material layers having recesses to accommodate their respective leads, with specific orientations of these leads relative to the battery's center, along with a separator and an electrolyte.

The core inventive concept of US12278330 is the integration of leads into recesses within the active material layers of both positive and negative electrodes to reduce overall battery thickness and improve energy density, while also addressing safety and performance aspects. While the patent's description and dependent claims highlight insulating layers for enhanced safety, the independent claims 1 and 11 primarily focus on the structural arrangement of the recessed leads.

Combination 1: US5154993A and General Knowledge in the Art

Reference 1: US5154993A (Eveready Battery Company, Inc.)

• Disclosure: US5154993A describes "electrode strips for coiled assemblies" with a "non-active region having a reduced thickness recess formed therein to accommodate a terminal tab" [cite: US12278330B2]. This patent clearly teaches the fundamental concept of creating a recess in an electrode layer to embed a terminal tab, specifically for reducing the overall thickness of a coiled battery. The concept is general and can be applied to both positive and negative electrodes.

Elements of Claims 1 and 11 taught by US5154993A:

• An electrode (either positive or negative) comprising a current collector and an active material layer.
• A recess within the active material layer.
• A lead (terminal tab) accommodated within the recess and coupled to the current collector.
• The underlying purpose of reducing battery thickness.

Missing Elements in US5154993A for Claims 1 and 11:

• Explicitly having both a positive electrode with a first recess for a positive lead and a negative electrode with a second recess for a negative lead in a single battery.
• Specific active materials like lithium cobalt oxide for the positive electrode and graphite or silicon for the negative electrode (specified in Claim 1).
• The specific orientations of the leads: positive lead "disposed on a surface of the positive current collector facing a center of the battery"; negative lead "disposed on a surface of the negative current collector facing away from the center of the battery"; and "a portion of the negative current collector where the negative lead is disposed extends towards the center of the battery."
• The inclusion of a separator and an electrolyte, which are fundamental components of a lithium-ion battery.

Motivation for a PHOSITA to Combine:
A PHOSITA, faced with the long-standing industry goal of creating thinner, higher energy density lithium-ion batteries, would recognize the value of the thickness-reducing technique taught by US5154993A. It would be obvious to apply this principle to both the positive and negative electrodes within a single lithium-ion battery cell to maximize the benefit of thickness reduction across the entire cell. The selection of conventional active materials, such as lithium cobalt oxide for positive electrodes and graphite or silicon for negative electrodes, was routine practice in lithium-ion battery design.

Furthermore, the specific orientations of the positive and negative leads ("facing a center" or "facing away from the center") and the extension of the negative current collector, are routine engineering design choices for optimizing the internal layout of wound or stacked battery cells. A PHOSITA would be motivated to arrange the leads in such specific ways to:

1. Facilitate assembly: Ensure smooth winding or stacking, preventing mechanical interference.
2. Optimize current collection: Route current efficiently to external terminals.
3. Prevent short circuits: Stagger or separate positive and negative leads effectively to maintain electrical insulation and enhance safety, a known concern in battery design as highlighted in the background of US12278330.
4. Achieve compactness: Minimize wasted space within the battery casing.

These specific orientations would be a natural outcome of conventional battery design considerations when implementing the recessed lead structure taught by US5154993A to achieve a compact, high-performance, and safe lithium-ion battery. The fundamental components of a separator and electrolyte are universally understood to be essential for any functional lithium-ion battery.

Combination 2: US20060051662A1 and General Knowledge in the Art

Reference 1: US20060051662A1 (Kwak Yoon T)

• Disclosure: US20060051662A1 explicitly teaches an "electrode assembly and a rechargeable battery using the same has a small thickness and a high capacity, because the electrode tab is embedded in the active material layer and does not increase the thickness of the battery" [cite: US12278330B2]. This reference directly and clearly articulates the problem of lead-induced thickness increase in batteries and provides the solution of embedding electrode tabs within the active material layer.

Elements of Claims 1 and 11 taught by US20060051662A1:

• An electrode assembly for a rechargeable battery with small thickness and high capacity.
• Electrode tabs (leads) embedded in the active material layer.
• The direct benefit of not increasing battery thickness due to the tabs.

Missing Elements in US20060051662A1 for Claims 1 and 11:

• Specific disclosure of applying the embedding technique to both positive and negative electrodes in a single battery, though the goal for the "electrode assembly" implies a holistic approach.
• Specific active materials like lithium cobalt oxide for the positive electrode and graphite or silicon for the negative electrode.
• The precise orientations of the leads as specified in the claims (positive lead "facing center," negative lead "facing away from center," and the current collector extension).
• The inclusion of a separator and an electrolyte.

Motivation for a PHOSITA to Combine:
A PHOSITA would be strongly motivated to employ the teachings of US20060051662A1 to develop lithium-ion batteries with reduced thickness and enhanced energy density, as the reference explicitly highlights these advantages. The objective of achieving "small thickness and a high capacity" for the entire electrode assembly would inherently lead a PHOSITA to apply the electrode tab embedding technique to both the positive and negative electrodes.

As with Combination 1, the choice of standard active materials (LiCoO2, graphite/silicon) for lithium-ion batteries is a matter of routine selection. The particular orientations of the positive and negative leads and the specific extension of the negative current collector are well within the purview of routine optimization for battery cell design. A PHOSITA would routinely consider such arrangements to:

1. Improve electrical performance by efficient current collection.
2. Enhance mechanical integrity during manufacturing (e.g., winding).
3. Prevent internal short circuits and improve overall safety, which is a critical aspect of lithium-ion battery design.
4. Achieve the most compact cell possible.

Therefore, a PHOSITA combining the clear teaching of US20060051662A1 to embed electrode tabs for thickness reduction with general knowledge of lithium-ion battery materials and routine design optimizations for lead routing would arrive at the subject matter of independent Claims 1 and 11 as an obvious modification to achieve predictable results, such as reduced internal resistance and improved volumetric energy density, as shown in US12278330's own Table 2.

To provide a comprehensive analysis for US Patent 12278330 regarding patent term adjustments, extensions, related applications, and expiration, I will consult the patent document itself and general USPTO rules on patent term calculation.

Patent Term Adjustment (PTA)

Patent Term Adjustment (PTA) adds days to the term of a patent to compensate for certain delays caused by the USPTO during the patent prosecution process. This can occur if the USPTO fails to:

• Issue an office action or notice of allowance within 14 months of the application filing.
• Act on a reply within four months.
• Act on an application within four months after a decision by the Patent Trial and Appeal Board (PTAB) or a federal court.
• Issue a patent within four months after payment of an issue fee.
• Issue the patent within three years of the actual filing date of the application.

The USPTO calculates PTA at the time the patent issues, and this information is typically included in the Issue Notification Letter. While the specific PTA for US12278330 is not explicitly detailed in the provided Google Patents abstract or description, the "Legal Events" section of the patent record would typically contain this information once the patent has issued. Since the issue date was April 15, 2025, the final PTA calculation would have been made. However, without direct access to the USPTO Patent Center for a detailed event history, the exact PTA days cannot be determined from the provided text.

Patent Term Extension (PTE)

Patent Term Extension (PTE) is available for patents on certain products (e.g., human drugs, medical devices, food additives) that require premarket regulatory approval, to restore time lost during the regulatory review process.

Based on the title "Lithium-ion battery having desirable safety performance" and the technical field, US Patent 122778330 is related to battery technology, not products subject to premarket regulatory review by agencies like the FDA. Therefore, it is highly unlikely that this patent would be eligible for a Patent Term Extension (PTE) under 35 U.S.C. § 156.

Continuation and Divisional Applications

The patent text indicates that US12278330 is a continuation of several prior U.S. patent applications:

• U.S. patent application Ser. No. 17/746,755, filed May 17, 2022. [cite: US12278330B2]
• U.S. patent application Ser. No. 17/407,081, filed Aug. 19, 2021. [cite: US12278330B2]
• U.S. patent application Ser. No. 16/113,938, filed Aug. 27, 2018. [cite: US12278330B2]
• U.S. patent application Ser. No. 14/596,873, filed Jan. 14, 2015. [cite: US12278330B2]

These are explicitly identified as "continuation" applications. There is no mention of "divisional" applications for US12278330 in the provided patent text. Divisional applications typically arise from a restriction requirement by the examiner, where an application claims two or more independent and distinct inventions.

Related Family Members

The patent states it claims priority to Chinese Patent Application No. 201420030319.4, filed January 17, 2014. [cite: US12278330B2] This Chinese application is considered a related family member. Additionally, the chain of continuation applications listed above are also related family members.

The "Family Applications" section on Google Patents also lists the following as related to the same priority date of 2014-01-17:

• US14/596,873 (US10541441B2) [cite: US12278330B2]
• US16/113,938 (US20180366775A1) [cite: US12278330B2]
• US17/407,081 (US20210384548A1) [cite: US12278330B2]
• US17/746,755 (US11923498B2) [cite: US12278330B2]
• US18/532,838 (US12278329B2) [cite: US12278330B2]
• US18/532,841 (US12278330B2) [cite: US12278330B2]
• CN201420030319.4U (CN203733894U) [cite: US12278330B2]

Projected Expiration Date

The standard term for a U.S. utility patent filed on or after June 8, 1995, is 20 years from its earliest effective filing date, excluding any Patent Term Adjustments (PTA) or extensions.

The earliest priority date for US12278330 is January 17, 2014, from Chinese Patent Application No. 201420030319.4. The earliest U.S. filing date from which priority is claimed is January 14, 2015, for U.S. patent application Ser. No. 14/596,873. [cite: US12278330B2] For the purpose of calculating the 20-year term, the earliest effective U.S. filing date is used. In this case, it refers back to the filing date of the earliest application in the chain for which a benefit is claimed under 35 U.S.C. §§ 120, 121, 365(c), or 386(c).

Since US12278330 claims priority back to the application filed on January 14, 2015 (US14/596,873), the 20-year term would typically run from this date.

Therefore, the base expiration date would be January 14, 2035.

However, this calculation does not account for any Patent Term Adjustment (PTA). As previously mentioned, the exact PTA is not available from the provided text. The Google Patents record indicates an "Anticipated expiration" date of 2035-01-14 [cite: US12278330B2], which aligns with the 20-year term from the earliest U.S. filing date. This suggests that either there was no PTA, or any PTA was effectively offset by applicant delay, or the displayed "Anticipated expiration" date does not factor in PTA. Without the official USPTO calculation for PTA, this remains the projected expiration date. No Patent Term Extension (PTE) is expected.

Defensive Disclosure: US Patent 12278330 - Lithium-ion battery having desirable safety performance

This document outlines derivative variations of the core inventive concepts disclosed in US Patent 12278330, with the aim of creating defensive prior art. These disclosures are designed to render future incremental improvements or alternative implementations by competitors obvious or non-novel, thereby limiting the scope of potential future patent claims.

The core claims of US12278330, particularly Independent Claims 1 and 11, describe a lithium-ion battery with recessed positive and negative leads in their respective active material layers, specific lead orientations relative to the battery center, and the inclusion of a separator and electrolyte. Dependent claims further introduce insulating glue layers. The following derivatives expand upon these core concepts across various axes.

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Derivative Variations Based on Core Claims (Claims 1 & 11)

1. Material & Component Substitution

Derivative 1.1: Solid-State Electrolyte and Composite Current Collectors

Enabling Description:
A lithium-ion battery structure as described in US12278330, wherein the liquid electrolyte is entirely replaced by a solid-state electrolyte (SSE), such as a polymer-based SSE (e.g., polyethylene oxide with lithium salts), a sulfide-based SSE (e.g., Li6PS5Cl), or an oxide-based SSE (e.g., LLZO). The separator is consequently integrated or eliminated. The positive current collector, instead of aluminum foil, comprises a graphene-aluminum composite, offering enhanced conductivity and mechanical strength, particularly within the first recess. The negative current collector, instead of copper foil, is a carbon nanotube (CNT)-copper mesh composite, providing improved flexibility and surface area for active material adhesion, especially around the second recess and its extending portion. The positive and negative leads are fabricated from lithium-doped aluminum alloys and lithium-doped copper alloys, respectively, ensuring improved interface stability with the solid-state active materials. The insulating glue layers are replaced by thin, high-dielectric ceramic coatings (e.g., Al2O3, SiO2) applied via atomic layer deposition (ALD) onto the exposed current collector surfaces within the recesses and on the lead surfaces.

classDiagram
    class LithiumIonBattery {
        +PositiveElectrode
        +NegativeElectrode
        +SolidStateElectrolyte
    }
    class PositiveElectrode {
        +GrapheneAluminiumCompositeCollector
        +PositiveActiveMaterialLayer
        +FirstRecess
        +LithiumDopedAluminiumLead
        +CeramicCoating(Insulation)
    }
    class NegativeElectrode {
        +CNTCopperMeshCollector
        +NegativeActiveMaterialLayer
        +SecondRecess
        +LithiumDopedCopperLead
        +CurrentCollectorExtension
        +CeramicCoating(Insulation)
    }
    class SolidStateElectrolyte {
        +Polymer/Sulfide/OxideType
    }
    LithiumIonBattery "1" -- "1" PositiveElectrode
    LithiumIonBattery "1" -- "1" NegativeElectrode
    LithiumIonBattery "1" -- "1" SolidStateElectrolyte
    PositiveElectrode "1" -- "1" SolidStateElectrolyte : interfaces with
    NegativeElectrode "1" -- "1" SolidStateElectrolyte : interfaces with

Derivative 1.2: Alternative Active Materials and Recess Formation

Enabling Description:
A lithium-ion battery according to US12278330, where the positive electrode active material layer utilizes Lithium Iron Phosphate (LFP) (LiFePO4) or Lithium Nickel Manganese Cobalt Oxide (NMC) (LiNiMnCoO2) instead of lithium cobalt oxide. The negative electrode active material layer employs hard carbon or lithium titanate (LTO) as an alternative to graphite or silicon. The first and second recesses are formed using a focused ion beam (FIB) milling process, allowing for nanoscale precision in recess dimensions and smoother edges, reducing the risk of active material delamination, particularly in the regions where the negative current collector extends towards the battery center. The leads are connected via cold welding or ultrasonic bonding, eliminating the heat-affected zone associated with soldering or laser welding, and improving the mechanical integrity of the lead-current collector interface.

flowchart TD
    A[Start] --> B(Select Active Materials);
    B --> C{Positive: LFP/NMC?};
    C -- Yes --> D(Negative: Hard Carbon/LTO);
    D --> E(Form Recesses via FIB Milling);
    E --> F(Connect Leads via Cold Welding/Ultrasonic Bonding);
    F --> G[End Battery Assembly];

2. Operational Parameter Expansion

Derivative 2.1: Micro-Scale Battery for MEMS/IoT Applications

Enabling Description:
A lithium-ion battery with recessed leads, miniaturized for micro-electromechanical systems (MEMS) or Internet of Things (IoT) devices. The positive and negative active material layers, with thicknesses on the order of 1-10 micrometers, are patterned onto thin-film current collectors (e.g., sputtered gold or platinum). The first and second recesses, with dimensions in the micrometer range (e.g., length 10-500 µm, width 1-50 µm), are fabricated using photolithography and reactive ion etching (RIE). The leads are micro-tabs formed by electrodeposition of copper or gold, connected to the current collectors via anisotropic conductive films (ACF) or localized laser micro-welding. The battery operates at reduced current densities (e.g., C/10 to C/100) suitable for low-power IoT applications, and at operating temperatures ranging from -40°C to 85°C, enabled by specialized ceramic solid-state electrolytes.

stateDiagram
    [*] --> Standby : Low Power
    Standby --> Active : Demand Surge
    Active --> Standby : Power Save
    Active --> Charging : External Power
    Charging --> Active : Full Charge
    Standby --> Hibernation : Long Term Storage
    Hibernation --> Standby : Wake Up Signal
    Active --> OverheatFault : > 85°C
    OverheatFault --> Shutdown : Safe Operation
    Standby --> ColdFault : < -40°C
    ColdFault --> Warming : Initiate Thermal Management

Derivative 2.2: High-Power, High-Temperature Industrial Storage

Enabling Description:
A large-format lithium-ion battery cell with recessed leads, optimized for high-power industrial energy storage, operating at elevated temperatures (e.g., 60°C to 120°C). The positive and negative active material layers feature high-thermal-stability active materials (e.g., LiFePO4 for positive, graphite with ceramic coatings for negative). The current collectors are thick, thermally stable alloys (e.g., nickel-clad copper for negative, aluminum alloys for positive). The first and second recesses are deep, accommodating robust leads capable of carrying currents up to several hundred amperes. The leads are formed from laminated copper-aluminum busbars, resistance welded into the recesses. The insulating layers comprise high-temperature polyimide films or ceramic fiber papers, extending beyond the recess edges to ensure robust thermal and electrical isolation. Forced air or liquid cooling channels are integrated directly adjacent to the electrode stack containing the recessed leads, designed for efficient heat removal from these critical current collection points.

flowchart LR
    A[High-Temp Active Materials] --> B(Thick Alloy Current Collectors);
    B --> C(Deep Recesses & Laminated Busbar Leads);
    C --> D(Resistance Welding);
    D --> E[High-Temp Polyimide/Ceramic Insulation];
    E --> F{Integrated Cooling Channels};
    F --> G(Industrial Storage Battery);

3. Cross-Domain Application

Derivative 3.1: Aerospace (High-Altitude Drones/Satellites)

Enabling Description:
A lithium-ion battery with recessed leads for high-altitude drones or satellites, prioritizing extreme low weight and vacuum compatibility. The positive and negative active material layers are highly porous, lightweight compositions (e.g., sulfur-carbon composite for positive, silicon nanowire array for negative) directly grown on ultra-thin, laser-perforated graphene current collectors. The first and second recesses are created by selective removal of active material via laser ablation, optimized for minimal mass. Leads are thin, flexible beryllium-copper ribbons, diffusion bonded to the current collectors within the recesses. The battery utilizes a gel polymer electrolyte to maintain performance under vacuum and extreme temperature cycling (e.g., -60°C to 100°C), minimizing outgassing. The insulating layers are composed of lightweight, radiation-hardened polyimide films integrated directly during the electrode manufacturing process.

sequenceDiagram
    participant Electrode Fabricator
    participant Drone Assembly
    participant Satellite Deployment

    Electrode Fabricator->>Electrode Fabricator: Laser-perforate graphene current collector
    Electrode Fabricator->>Electrode Fabricator: Grow Si nanowire / S-C active material
    Electrode Fabricator->>Electrode Fabricator: Laser ablating recesses
    Electrode Fabricator->>Electrode Fabricator: Diffusion bond Be-Cu leads
    Electrode Fabricator->>Electrode Fabricator: Apply radiation-hardened polyimide insulation
    Drone Assembly->>Electrode Fabricator: Request Lightweight Battery
    Electrode Fabricator->>Drone Assembly: Deliver Battery Cells
    Drone Assembly->>Drone Assembly: Integrate into Drone Structure
    Drone Assembly->>Satellite Deployment: Drone Operates at High Altitude
    Satellite Deployment->>Satellite Deployment: Battery Performs in Vacuum & Extreme Temps

Derivative 3.2: Medical Implants (Pacemakers/Neural Interfaces)

Enabling Description:
A miniature, biocompatible lithium-ion battery with recessed leads, suitable for long-term medical implants. The active material layers are ultra-thin (e.g., 5-20 µm), deposited by sputtering or pulsed laser deposition (PLD) onto flexible, biocompatible titanium current collectors. The first and second recesses are micro-etched features, accommodating flexible platinum-iridium leads. These leads are laser micro-welded within the recesses, with the welding points encapsulated by a thin layer of medical-grade Parylene C to ensure biocompatibility and electrical isolation. The entire battery is hermetically sealed within a titanium casing and operates with a non-flammable ionic liquid electrolyte. The insulating glue layers, where present, are biocompatible silicone-based elastomers that conform to the recess geometry.

classDiagram
    class MedicalImplantBattery {
        +MiniatureSize
        +Biocompatible
        +LongTermStability
    }
    class PositiveElectrode {
        +SputteredActiveMaterial
        +TitaniumCurrentCollector
        +MicroEtchedRecess
        +PtIrLead
        +ParyleneCEncapsulation
        +BiocompatibleInsulation
    }
    class NegativeElectrode {
        +SputteredActiveMaterial
        +TitaniumCurrentCollector
        +MicroEtchedRecess
        +PtIrLead
        +ParyleneCEncapsulation
        +BiocompatibleInsulation
    }
    class IonicLiquidElectrolyte {
        +NonFlammable
        +Biocompatible
    }
    MedicalImplantBattery "1" -- "1" PositiveElectrode
    MedicalImplantBattery "1" -- "1" NegativeElectrode
    MedicalImplantBattery "1" -- "1" IonicLiquidElectrolyte

Derivative 3.3: Automotive (Electric Vehicle Structural Batteries)

Enabling Description:
A structural lithium-ion battery cell with recessed leads, designed to be integrated directly into electric vehicle chassis components. The positive and negative current collectors are carbon fiber composites with embedded metallic meshes (e.g., copper for negative, aluminum for positive), providing both structural integrity and electrical conductivity. The active material layers are applied directly to these composite collectors. The first and second recesses are integrally molded features within the composite current collectors, reinforced with localized polymer matrices. High-strength aluminum or copper busbar leads are co-cured into these molded recesses, forming a robust, multi-functional connection. The insulating glue layers consist of epoxy resins with high dielectric strength, also co-cured during the composite fabrication, providing enhanced mechanical and electrical isolation within the load-bearing structure.

graph TD
    A[Carbon Fiber Composite Current Collector] --> B{Molded Recess};
    B --> C[Co-cured Busbar Lead];
    C --> D[Integrated Epoxy Insulation];
    D --> E[Active Material Application];
    E --> F[Structural Battery Cell];
    F --> G[EV Chassis Integration];

4. Integration with Emerging Tech

Derivative 4.1: AI-Optimized Recess Design and Placement with IoT Monitoring

Enabling Description:
A lithium-ion battery system where the design and placement of the first and second recesses, along with the dimensions and materials of the positive and negative leads, are continuously optimized by an AI algorithm during manufacturing and throughout the battery's lifecycle. The AI analyzes real-time sensor data from embedded IoT sensors (micro-thermocouples, strain gauges, impedance sensors) within each cell, focusing on the regions around the leads and recesses. These sensors transmit data on internal temperature, mechanical stress, and localized impedance, which the AI uses to predict potential degradation or short-circuit risks. Based on these predictions, the AI can suggest modifications to the recess geometry (e.g., laser ablation paths), lead material compositions (e.g., graded alloys), or even initiate targeted healing mechanisms (e.g., polymer sealant injection into micro-cracks detected by strain gauges). Blockchain technology is used to immutably record each cell's manufacturing parameters, material provenance, and all collected IoT performance data, enabling verifiable traceability and quality assurance.

flowchart TD
    A[AI Design Optimization Engine] --> B(Manufacturing Control System);
    B --> C(Electrode Fabrication Line);
    C --> D[Battery Cell with Recessed Leads];
    D -- Real-time Data --> E(Embedded IoT Sensors);
    E --> F(Data Aggregation Platform);
    F -- Encrypted & Hashed --> G(Blockchain Ledger);
    G --> A;
    G --> H(Quality Assurance/Traceability);
    E --> A;

Derivative 4.2: Self-Diagnosing Battery with Adaptive Insulating Layers

Enabling Description:
A lithium-ion battery where the insulating glue layers (first and second) are made of electro-responsive polymer composites that can dynamically change their dielectric properties or self-heal in response to localized internal electric fields, temperature excursions, or mechanical stress detected by integrated nanoscale sensors. An embedded microcontroller processes data from these sensors (e.g., distributed capacitance sensors within the insulating layers) to identify micro-shorts or potential breakdown points. Upon detection, the insulating material can locally swell or polymerize, effectively reinforcing the insulation. Furthermore, the battery employs an energy harvesting system, converting stray electromagnetic fields within the battery or mechanical vibrations into electrical energy to power the internal sensor network and microcontroller, thereby eliminating the need for external power for monitoring.

stateDiagram
    state "Normal Operation" as Normal
    state "Micro-Short Detected" as MicroShort
    state "Insulation Reinforced" as Reinforced
    state "Energy Harvesting" as Harvest

    Normal --> MicroShort : Sensor Detects Anomaly
    MicroShort --> Reinforced : Electro-Responsive Polymer Reacts
    Reinforced --> Normal : Anomaly Resolved
    Normal --> Harvest : Continuously Power Sensors
    MicroShort --> Harvest : Power for Reaction
    Reinforced --> Harvest : Power for Maintenance

5. The "Inverse" or Failure Mode

Derivative 5.1: Fail-Safe Thermal Runaway Mitigation System

Enabling Description:
A lithium-ion battery as described, augmented with a multi-stage fail-safe mechanism designed to prevent catastrophic thermal runaway. The positive and negative leads, in addition to being recessed, incorporate embedded fusible links with varying melting points. The first stage involves a low-temperature fusible link within the lead (e.g., a tin-bismuth alloy) that severs the electrical connection if the local temperature at the recess exceeds a pre-defined threshold (e.g., 90°C), preventing further current flow. The second stage involves a thermally activated polymer layer (e.g., shape memory polymer) directly surrounding the current collector extension and recesses. Upon reaching a higher temperature threshold (e.g., 120°C), this polymer undergoes a phase change, expanding rapidly to physically separate the electrodes or encapsulate the active material, preventing propagation of thermal runaway. The electrolyte further contains microcapsules of a fire-retardant agent that rupture and release upon internal pressure increase or elevated temperature.

flowchart TD
    A[Normal Operation] --> B{Thermal Event Detected > 90°C};
    B -- Yes --> C[Low-Temp Fusible Link Activated];
    C --> D(Electrical Circuit Severed);
    D --> E{Thermal Event Continues > 120°C};
    E -- Yes --> F[Thermally Activated Polymer Expands];
    F --> G(Electrode Separation / Encapsulation);
    F --> H[Fire-Retardant Microcapsules Rupture];
    G & H --> I[Thermal Runaway Mitigation];
    B -- No --> A;
    E -- No --> D;

Derivative 5.2: Low-Power, Limited-Functionality Mode for Extended Standby

Enabling Description:
A lithium-ion battery designed with a specific architecture and control system that allows it to enter a very low-power, limited-functionality mode for extended standby periods without significant self-discharge or degradation. This is achieved by segmenting the active material layers and their respective recesses. The battery can electrically isolate specific segments of the positive and negative electrodes, effectively reducing the active area and electrolyte contact for certain periods. This isolation is managed by micro-switches or electro-responsive gate materials within the current collectors near the recesses. In low-power mode, only a minimal set of electrode segments with their recessed leads are active to provide essential functions (e.g., maintaining a small clock or memory). The insulating glue layers are designed to maintain their integrity even under partial delamination of active material from inactive segments, preventing any unintended electrical contact. The negative current collector extension for the active segment is further protected by a self-passivating coating to minimize parasitic reactions during long standby.

stateDiagram
    [*] --> FullPowerMode
    FullPowerMode --> LowPowerMode : User/System Command
    LowPowerMode --> DeepSleepMode : Extended Inactivity
    DeepSleepMode --> LowPowerMode : Wake-up Trigger
    LowPowerMode --> FullPowerMode : User/System Command

    state FullPowerMode {
        AllSegmentsActive : Max Capacity/Power
    }
    state LowPowerMode {
        SegmentedActiveArea : Reduced Consumption
        MicroSwitchesActive : Isolate Segments
    }
    state DeepSleepMode {
        MinimalActiveArea : Ultra Low Consumption
        SelfPassivatingCoating : Protect Inactive Negative Collector
    }

---

Combination Prior Art Scenarios with Open-Source Standards

The core inventions of US12278330 relate to the structural features of embedding leads within electrode active material layers for thickness reduction and enhanced safety. Combining this with existing open-source standards can make further developments obvious.

Scenario 1: Recessed Lead Battery + CAN Bus for BMS

Combination: The lithium-ion battery design from US12278330, particularly with its emphasis on safety and optimized space utilization, integrated with a Battery Management System (BMS) that communicates using the Controller Area Network (CAN) Bus open standard (ISO 11898).

Enabling Description: A battery module comprising multiple lithium-ion cells, each featuring the recessed positive and negative leads and associated insulating layers as detailed in US12278330. Each cell integrates a micro-BMS circuit for local voltage, current, and temperature monitoring. These micro-BMS units communicate their data to a central BMS controller via a CAN bus network. The CAN bus allows for robust, real-time data exchange within the battery module, enabling the central BMS to monitor the state of charge (SoC), state of health (SoH), and internal temperatures of individual cells, especially detecting anomalies near the recessed lead areas. The CAN protocol's error detection and fault tolerance capabilities provide a standardized, reliable communication backbone for managing the safety performance (e.g., thermal runaway events) improved by the recessed lead structure.

Scenario 2: Recessed Lead Battery + MQTT for IoT Telemetry

Combination: The lithium-ion battery with recessed leads (US12278330) equipped with IoT sensors that transmit operational data using the Message Queuing Telemetry Transport (MQTT) open standard (ISO/IEC PRF 20922).

Enabling Description: A lithium-ion battery cell with recessed positive and negative leads, further incorporating miniaturized IoT sensors (e.g., temperature, internal resistance, strain) strategically placed near the recesses and current collector extensions. These sensors are wirelessly connected to a low-power microcontroller within the battery pack. The microcontroller periodically publishes telemetry data from the cells to a central MQTT broker over a wireless network (e.g., Wi-Fi, Bluetooth Low Energy). This standardized lightweight messaging protocol enables efficient, low-bandwidth communication of battery health and safety parameters to remote monitoring systems, predictive maintenance platforms, or user interfaces. The MQTT protocol's publish/subscribe model is ideal for scalable real-time monitoring of a fleet of batteries, leveraging the safety and energy density benefits derived from the recessed lead design.

Scenario 3: Recessed Lead Battery + SPDX for Supply Chain Traceability

Combination: Lithium-ion batteries manufactured with the structural features of US12278330, with their material provenance and manufacturing history documented using the Software Package Data Exchange (SPDX) standard (ISO/IEC 5962:2021) or a similar bill of materials standard.

Enabling Description: A manufacturing process for lithium-ion batteries incorporating the recessed lead structures of US12278330. For each batch of active materials, current collectors, leads, separators, and insulating layers used, a detailed SPDX document (or an equivalent open-source-compatible Bill of Materials (BOM) standard) is generated. This document records the supplier, chemical composition, material certifications, and the specific manufacturing steps (e.g., laser cleaning, welding parameters for lead attachment, glue layer application) relevant to the creation of the recessed lead assembly. This SPDX-compliant data is then associated with unique identifiers for each battery cell or batch. This allows for transparent and verifiable tracking of all components and processes throughout the battery's supply chain, enhancing quality control, facilitating recall management, and ensuring adherence to safety standards, thereby complementing the inherent safety improvements provided by the recessed lead design and insulating layers.