Fast charging EV batteries aren’t just a time-saver but a game-changer, transforming the prospects of EVs for every potential buyer.

A groundbreaking study featured in IEEE Transactions on Control Systems Technology unveils a revolutionary approach. Instead of charging all cells in a battery pack the same way, carefully controlling the electric current to each cell reduces damage, helping each cell last longer and perform better.

Preliminary simulations hint at a remarkable 20% increase in charge-discharge cycles, even amidst frequent fast charging sessions.

In this blog, we will look into these advancements, the reason behind faster charge rates, and explore the innovative patents steering this electric revolution in the upcoming sections. 

The Challenges of Fast Charging EV Batteries

Fast charging EV batteries, while a key factor in increasing EV adoption, bring convenience along with some challenges. Some of these are:

1. Fast Charging and Heat Generation: Fast charging of EV batteries results in more heat. This heat degenerates the battery, making it less efficient. 
2. Temperature Control: Determining the optimal charging temperature based on vehicle driving conditions and battery charge status is difficult as it requires sophisticated algorithms.
3. Heat Dissipation: Effectively dissipating heat during and after fast charging to prevent temperature spikes requires innovative solutions, such as phase change composite layers.
4. Dynamic Driving Conditions: Adapting to varying and dynamic driving conditions demands advanced monitoring and prediction systems.

Latest Research In Fast Charging EV Batteries

Each of these areas holds the potential to revolutionize the fast charging of EV batteries, making electric vehicles more efficient worldwide.

1. Advanced Battery Chemistries More Resistant to Heat and Fast Charging 

Advanced fast charging EV battery chemistries are being developed to address electric vehicle (EVs) safety concerns. Lithium Ferro Phosphate (LFP) batteries are an advanced form of battery chemistry. They are safer than other widely used fast charging EV batteries due to their lithium composition.  

These can also be recycled by the process that involves separating the components of the batteries to recover valuable metals like cobalt, nickel, manganese, and lithium. 

2. Promising Technologies

Some more evolving batteries that are taking research to the next level include:

1. Lithium Titanate Batteries– Lithium titanate batteries have become increasingly popular rechargeable batteries, offering numerous advantages over other lithium technologies. They are considered the safest among lithium batteries and use lithium titanate oxide as the anode material. The anode material impacts the properties of fast charging EV batteries as ions move from one electrode to another. 
   
   Toshiba has developed lithium titanate batteries with 90% charging capacity in just 10 minutes. [Source]
2. Lithium Iron Phosphate (LiFePO₄) Batteries LiFePO₄ batteries use lithium iron phosphate as the cathode material. They have a higher discharge rate, longer cycle life, and higher temperature tolerance compared to other types of lithium-ion batteries. They are also safer due to their lower operating voltage and more stable chemistry.
3. Lithium Cobalt Oxide (LiCoO₂) Batteries These fast charging EV batteries are widely used in portable electronics due to their high energy density. However, they have a relatively short lifespan and can pose safety risks if not properly managed. 
   
   Nichia Corporation produces lithium cobalt oxide batteries that are used in electric vehicles and other industrial applications. [Source]

4. Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO₂ or NMC) Batteries NMC batteries are commonly used as fast charging EV batteries and energy storage systems due to their high energy density and long cycle life.

3. Novel Battery Cooling Systems 

A new cooling system for battery packs uses a metal part that conducts heat and is placed around the battery. This setup helps get rid of the heat made by fast charging EV batteries. Here’s what’s new in this area:

1. Liquid Cooling Technologies: Liquid cooling, due to its high thermal conductivity, is widely used in battery thermal management systems. The system uses a cooling liquid that circulates around the battery cells to absorb and dissipate heat.
2. Design Improvements and Optimization: Recent advancements have focused on improving the design of liquid-cooled cooling systems. This includes fine-tuning the cooling liquid, system structure, and hybrid systems.
   
   For instance, different liquids such as oil, electrical media, and added liquid metals and nanoparticles are being explored as coolants.
3. Phase Change Materials (PCMs): PCMs are being used in hybrid thermal management systems. These materials absorb and release thermal energy during the process of melting and freezing.
   
   One of the patents describes a method for processing phase change material, including providing pieces of phase change material with a transition temperature. The pieces of phase change material are combined with a medium to form a mixture. The mixture is supplied to a tool that forms a phase change material product. 
   
   Rogers Corporation has expanded its HeatSORB phase-change materials that optimise the temperature during usage by capturing the heat. [Source]
4. Heat Pipes: Heat pipes are devices that transfer heat from one point to another. They are being used in combination with other cooling methods to enhance the cooling effect.
5. Air-Based Cooling Systems: These systems use air as a coolant to absorb and dissipate heat.
6. Innovative Schemes: Some novel schemes introduce components like a hollow spoiler prism and a spoiler prism filled with phase-change material with fins to enhance the heat transfer capacity and safety of a battery pack under a thermal runaway condition.

4. New Charge Algorithms 

New charging algorithms are being developed to optimize the rate of charging while monitoring temperature. These algorithms use specific charging algorithms for lithium-ion batteries.

5. Hardware and Infrastructure Innovations 

These include the development of AMD-powered hardware, all-flash storage arrays, pay-as-you-go consumption-based infrastructure, NVMe storage technology in on-premises servers, and ARM server processors. 

Recently, Purdue University engineers have invented a new, patent-pending charging station cable that would fully recharge certain electric vehicles in under five minutes. The cable can deliver a current 4.6 times that of the fastest available EV chargers on the market today by removing up to 24.22 kilowatts of heat.

6. Improving Charge Connectors, Power Electronics, Grid Interconnection 

There are ongoing efforts to develop multi-port 1+ MW grid-connected stations to recharge medium and heavy-duty electric vehicles. This includes the evaluation of vehicle charge connectors and the development of enhanced fast charging EV batteries that facilitate multi-port charge control.

7. Advanced Battery Materials

Advancements in fast-charging Electric Vehicle (EV) batteries hinge on sophisticated battery materials. Silicon-graphite composite anodes, combining silicon and graphite in optimized structures, promise high charge rates without lithium plating. The structural stability of graphite complements the rapid lithium ion absorption of silicon. 

On the other hand, larger nickel-rich cathode crystals with specific orientations enhance lithium ion diffusion pathways, facilitating faster charging. 

Conclusion

The balance between charging speed and battery lifespan is a promising area of research, with advancements in battery technology and thermal management playing a pivotal role. Fast charging EV Batteries such as Lithium Ferro Phosphate (LFP) and Lithium Titanate stand out due to their enhanced safety and thermal stability. 

In parallel, novel cooling systems, including liquid cooling and phase change materials, are being developed to combat heat-induced degradation, a common issue in fast charging. 

However, the widespread adoption of very fast charging is contingent on further advancements in charging algorithms and infrastructure. This includes the development of optimized charging algorithms specifically designed for lithium-ion batteries, as well as the establishment of multi-port grid-connected stations. Thus, a holistic approach is crucial. 

Accessing the latest research and patented technologies is essential to keep pace with these rapid advancements.

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