Techniques to Increase EV Battery Life

Battery temperature adjustment system for electric vehicles to prevent battery deterioration. The system has a battery, cooling device and control system. When the vehicle is connected to an external power source, the control system selects either the battery or external power to cool the battery based on a deterioration sensitivity map. If cooling with external power would cause more deterioration than using battery power, it cools with battery power.

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Battery charging method to improve battery life by reducing expansion force during charging. The method involves adjusting the charge rate when the battery's state of charge (SOC) reaches a certain range where expansion force is maximized. The charge rate is lowered when SOC is close to the range to reduce expansion force and prolong battery life. When SOC exceeds the range, the charge rate is raised to ensure efficiency. This optimizes charging near the expansion limit to extend battery cycle life.

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Electrodes for energy storage systems with improved performance and cycle life. The electrodes are made of materials like silicon, carbon-sulfur, lithium or graphene-silicon composites, coated with parylene. The parylene coating acts as a barrier to prevent contact between the electrode and the electrolyte. This reduces capacity fade and degradation from reactions between the electrode and electrolyte. The parylene coating also contains polysulfides in lithium-sulfur batteries to improve cycle life.

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Optimizing the operating lifetime of an energy storage system like a vehicle battery pack by monitoring parameters like temperature and voltage that indicate cell degradation. When a parameter approaches a threshold indicating end-of-life, the system heats the battery pack to extend its performance and lifetime.

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Apparatus for diagnosing the state of a vehicle battery and presenting measures to suppress battery degradation. The apparatus analyzes the battery usage history and presents suitable suppression measures for factors causing degradation. If an alternative measure doesn't meet certain criteria, it is prohibited from being presented. This prevents presenting ineffective measures that could restrict vehicle use without benefit. By selectively presenting only suitable measures, battery degradation can be suppressed without reducing the vehicle's value.

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Positive electrode material for all-solid-state lithium batteries with improved cycle life when using sulfur-based cathodes. The material consists of composite particles containing sulfur as the active material within a porous conductive matrix. The surface of the composite particles is coated with an electronic conductor. This configuration provides a conductive path through the composite particles to improve cycle durability compared to bare sulfur particles. The composite particles are made by mixing sulfur and the porous conductive material, heating to melt and fill the pores, then coating the surface.

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Charging system for batteries that optimizes charging efficiency by dynamically controlling temperature during charging operations. The system monitors the external power source's output and compares it with the previous output value during charging. When the current output value exceeds the previous one, the system adjusts the battery temperature target based on the current output value. This approach prevents the repetitive stopping and restarting of charging operations that can occur when the target temperature is updated too frequently. The system maintains the target temperature at a previously set value when the output value does not exceed the previous one, ensuring consistent charging conditions.

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Secondary battery with improved lifespan and charge rates by using fiberized binder in the positive electrode and granules in the negative electrode. The positive electrode has a fiberized binder that binds the active material and conductive material, while the negative electrode uses granules of active material bound by a binder. This balances the electrochemical reaction rates of the electrodes for improved overall battery lifespan.

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Battery module with enhanced thermal management through strategically integrated phase change materials (PCMs) that absorb heat generated in critical battery connections. The module features a bus bar with integrated phase change members that distribute heat from connecting areas between the cell tab and bus bar, while a secondary phase change member is positioned on the top surface of the cell. This dual-phase design enables targeted cooling of high-temperature areas, particularly the connecting region between the cell tab and bus bar, while maintaining overall system thermal balance. The phase change materials are designed to absorb and release heat efficiently, preventing thermal runaway and fire hazards.

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Electric vehicle power supply layout to improve cooling and ripple current absorption. The power supply components like inverters are arranged in an alternating pattern of power cards and link capacitors along a main axis. This interleaving improves cooling by creating channels between the components for airflow. It also reduces ripple currents by absorbing them in the link capacitors and isolating them from the power cards.

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Diagnosing abnormalities in voltage behavior of batteries based on changes in differences between measured open circuit voltage data and estimated open circuit voltage data over time. The method involves generating open circuit voltage (OCV) data from the battery, deriving estimated OCV data based on the measured data, and diagnosing battery health based on the difference between the measured and estimated OCV values. This allows detecting subtle voltage abnormalities even when the battery voltage itself doesn't change significantly.

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Diagnosing lithium-ion battery degradation during charging using resistance measurements. The method involves monitoring voltage changes during charging to calculate resistance of each battery cell. Resistance variations indicate degradation like lithium plating. By calculating average resistances for each SOC class, probabilities of abnormal cells can be determined. This allows diagnosing cells during normal charging without extended rests.

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An electric vehicle with a battery deterioration monitoring system that provides an easily accessible and tamper-proof display of battery degradation level. The system includes a battery gauge to measure the battery's state of charge, a battery deterioration meter to measure battery degradation level, and a display integrated into the vehicle's dashboard. The display shows the battery charge and degradation levels. This allows drivers to easily monitor both charge and degradation without needing external equipment. The display prevents tampering by being integrated into the vehicle's electrical system.

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Energy and thermal management system for fuel cell vehicles that optimizes performance and longevity by proactively cooling the fuel cell and battery in anticipation of increased load demands. The system uses route prediction to identify sections with expected high fuel cell loads. It then lowers the fuel cell temperature ahead of time to improve power density and prevent overheating during peak demand. It may also cool the battery, reduce maximum fuel cell power, increase battery charge, and adjust power split to further manage energy use.

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Secondary battery with integrated safety vent mechanism that enables repeated use of the battery's venting system. The battery features a case with an open side and a cap plate with a vent hole. A safety vent is positioned on the cap plate, comprising multiple layers that can be magnetically controlled to seal or open the vent. This design allows the battery to be charged and discharged multiple times while maintaining its venting capabilities. The safety vent's magnetic biasing system enables precise control over venting behavior, ensuring safe operation even after multiple charge cycles.

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Carbon structure for lithium-sulfur batteries with enhanced sulfur retention and improved electrode performance. The structure features a highly graphitic porous carbon matrix with a concave center surface that supports sulfur, while maintaining electrical conductivity. The structure is prepared through a metallothermic reduction process followed by acid etching, resulting in a stable sulfur-containing carbon matrix that suppresses shuttle phenomenon and maintains electrode shape during charging and discharging. The carbon matrix has a specific surface area and pore structure optimized for sulfur retention and electrical conductivity.

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A separator for lithium-ion batteries with improved heat resistance, thermal stability, and cycle life compared to conventional separators. The separator comprises a nanocellulose coating on a porous substrate with a surface tension ratio of 0.68 or higher. The nanocellulose can have modified groups like amines, carboxylic acids, sulfonic acids, borates, or phosphates. This enhances heat resistance and bonding strength. An adhesive layer can also be added to prevent coating delamination. The separator enables high energy density, safety, and cycle life in lithium-ion batteries.

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A heat exchanger design for cooling batteries in electric vehicles that provides more uniform cooling compared to traditional heat exchangers. The heat exchanger has two main flows, one for cooling the battery and another for circulating refrigerant. The refrigerant flow has multiple paths that branch and reconnect, allowing the refrigerant to move in parallel between the battery and the main flow. This creates a more complex flow path that promotes more uniform heat transfer between the battery and the refrigerant, which helps prevent hot spots and improves cooling efficiency.

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An assembled battery design that prevents state-of-charge (SOC) variations during charging by optimizing electrode positioning. The battery comprises stacked cells connected in series, where the negative-electrode composite layer is positioned above the positive-electrode active material layer. By maintaining the negative-electrode layer above the positive-electrode layer, the battery achieves improved state-of-charge uniformity during charging by minimizing electrode contact resistance. This design addresses the conventional issue of SOC variations in series-connected batteries by ensuring the negative-electrode layer remains above the positive-electrode layer during charging.

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A movable battery system for electric vehicles that enables independent charging, discharging, and thermal management of auxiliary batteries. The system comprises a separate battery pack mounted on the auxiliary vehicle, with its own cooling system and power management components. A thermal management module and power conversion module are integrated into the main vehicle's battery pack, while the auxiliary vehicle's battery has its own cooling system and thermal management components. The system allows the auxiliary vehicle's battery to be charged and discharged independently of the main vehicle's battery, with its own cooling and thermal management systems.

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