Electric vehicle batteries face multiple aging mechanisms that affect their usable capacity and power delivery capabilities. Field data shows that batteries can lose 2-3% capacity annually under normal usage patterns, with acceleration of degradation when exposed to extreme temperatures, high charge rates, or extended periods at high states of charge. These factors combine to determine the practical service life of battery packs that typically cost $5,000-15,000 to replace.

The fundamental challenge lies in balancing the competing demands of daily range requirements, fast charging convenience, and long-term battery preservation across widely varying operating conditions.

This page brings together solutions from recent research—including adaptive thermal management systems, intelligent charge rate optimization, strategic cell placement architectures, and state-of-charge management during extended parking. These and other approaches provide practical strategies for maximizing battery longevity while maintaining the performance expectations of electric vehicle owners.

1. Battery Cooling System with Deterioration Sensitivity-Based Power Source Selection

HONDA MOTOR CO., LTD., 2023

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.

US20230234474A1-patent-drawing

2. Battery Charging Method with Dynamic Charge Rate Adjustment Based on State of Charge Expansion Force Threshold

CONTEMPORARY AMPEREX TECHNOLOGY CO., LIMITED, 2023

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.

US20230238816A1-patent-drawing

3. Electrodes with Parylene Coating for Enhanced Stability in Energy Storage Systems

Rensselaer Polytechnic Institute, 2023

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.

4. Energy Storage System with Parameter-Triggered Thermal Management for Extended Cell Longevity

VOLVO TRUCK CORPORATION, 2019

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.

US10259338B2-patent-drawing

5. Vehicle Battery Diagnosis Apparatus with Selective Degradation Suppression Measure Presentation

Takeshi Fujita, Hideaki Hirose, Masanobu Hidaka, 2013

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.

US20130317690A1-patent-drawing

6. Intelligent Battery Management in a Hybrid Photovoltaic Using Fuzzy Logic System

joann v magsumbol, argel a bandala, alvin b culaba - Multidisciplinary Digital Publishing Institute, 2025

LiFePO4 batteries need a battery management system (BMS) to improve performance, extend their lifespan, and maintain safety by utilizing advanced monitoring, control, optimization techniques. This paper presents the design, development, implementation of an intelligent (i-BMS) that integrates real-time monitoring control batteries. The was extensively tested using multiple datasets, results show able temperature within set range, balance cell voltages, distribute energy according load prioritization. It uses fuzzy logic approach effectively manage farm requirements. Additionally, proposed method embedded three-level prioritization algorithm woven into rule allocate dynamically among essential, regular, non-essential loads.

7. Optimization of Electric Vehicle Charging and Discharging Strategies Considering Battery Health State: A Safe Reinforcement Learning Approach

shuifu gu, kejun qian, yongbiao yang - Multidisciplinary Digital Publishing Institute, 2025

With the widespread adoption of electric vehicles (EVs), optimizing their charging and discharging strategies to improve energy efficiency extend battery life has become a focal point current research. Traditional often fail adequately consider batterys state health (SOH), resulting in accelerated aging decreased efficiency. In response, this paper proposes safe reinforcement learningbased optimization method for EV strategies, aimed at minimizing costs while accounting SOH. First, novel status prediction model based on physics-informed hybrid neural networks (PHNN) is designed. Then, decision-making problem, considering status, formulated as constrained Markov decision process, an interior-point policy (IPO) algorithm long short-term memory (LSTM) proposed solve it. The filters out that violate constraints by introducing logarithmic barrier function. Finally, experimental results demonstrate significantly enhances maintaining maximum economic benefits during process. This research provides solution intelligent personalized EVs, which great significance promoting sustainable de... Read More

8. Fast-Charging Optimization Method for Lithium-Ion Battery Packs Based on Deep Deterministic Policy Gradient Algorithm

zhi zhang, tong guo, yefeng liu - Multidisciplinary Digital Publishing Institute, 2025

Fast-charging technology for lithium-ion batteries is of great significance in reducing charging time and enhancing user experience. However, during fast charging, the imbalance among battery cells can affect overall performance available capacity pack. Moreover, efficiency not only limited by itself but also closely related to optimization strategy. To address batteries, this paper proposes a method based on deep reinforcement learning. First, learning model constructed, aiming minimize SOC balancing cost, with constraints voltage, temperature, SOC, SOH. The employs deterministic policy gradient (DDPG) algorithm integrated reward centralization entropy regularization mechanisms, dynamically adjust current achieve an optimal balance between health. Experimental results indicate that proposed enhances efficiency, contributes extending life, supports safety process. Compared traditional constant-current constant-voltage (CCCV) strategy, improved DDPG strategy reduces total 60 s from 540 470 s. Furthermore, compared basic method, shows clear advantage efficiency.

9. Improving State-of-Health Estimation for Lithium-Ion Batteries Based on a Generative Adversarial Network and Partial Discharge Profiles

hangyu zhang, yingxin lai - Multidisciplinary Digital Publishing Institute, 2025

The aging effect weakens the capacity of lithium batteries, seriously affecting performance electric vehicles. Developing state-of-health estimation technology for batteries can help to optimize charging and discharging strategies This study investigates use partial discharge data SOH address unstable output traditional models when using under low-voltage conditions. first used DoppelGANger network generate artificially synthesized data. After augmentation process, we trained temporal convolutional construct a data-driven model. Finally, model was evaluated three indicators: RMSE, MAPE, delta. proposed method improved five kinds operating conditions in seven testing scenarios compared with models. experimental results provide practical solution estimation.

10. Domain Generalization Using Maximum Mean Discrepancy Loss for Remaining Useful Life Prediction of Lithium-Ion Batteries

wenbin li, yue yang, stefan pischinger - Multidisciplinary Digital Publishing Institute, 2025

The capacity of Lithium-ion batteries degrades over the time, making accurate prediction their Remaining Useful Life (RUL) crucial for maintenance and product lifespan design. However, diverse aging mechanisms, changing working conditions cell-to-cell variation lead to inhomogeneous cell complicated life prediction. In this work, a data-driven algorithm based on stacked Long Short Term Memory (LSTM) encoderdecoders is proposed RUL encoder upstream decoder form an autoencoder framework feature extraction. downstream encoderdecoder To enhance generalization during training, Maximum Mean Discrepancy (MMD) loss included in framework. similarity patterns analyzed splitting source target datasets through k-means Density-Based Spatial Clustering Applications with Noise (DBSCAN). Euclidean metric accumulated Equivalent Cycle Number (ECN) sequence shows better performance similarity-based data than Dynamic Time Wrapping (DTW) distance fading trajectory. experimental results indicate that can provide using 5% good R2 score 0.98.

11. Next-Gen Energy Storage: Graphene and Nanomaterials Powering the Nanotechnology Revolution

murali krishna pasupuleti, 2025

Abstract: This research paper investigates the transformative role of graphene and advanced nanomaterials in development next-generation energy storage systems, focusing on their potential to revolutionize battery technologies support global sustainability. By examining unique physicochemical properties nanomaterialssuch as high surface area, electrical conductivity, mechanical strengththe study explores how innovations graphene, carbon nanotubes, metal oxides, 2D materials are enhancing performance, efficiency, lifespan lithium-ion, solid-state, supercapacitor-based systems. The also addresses breakthroughs nanostructured electrode electrolyte design, synthesis techniques, integration with smart management Through a comprehensive analysis recent experimental industrial advancements, this work highlights nanotechnology is paving way for safer, faster-charging, more environmentally friendly solutions vital electric mobility, renewable integration, grid resilience. Keywords: Energy storage, Graphene, Nanomaterials, Next-generation batteries, Lithium-ion Solid-state Supercapacitor... Read More

12. Power Storage Module Housing with Duct Cover and Protrusions for Controlled Gas Venting

PANASONIC IP MAN CO LTD, 2025

Power storage module design with improved gas venting to prevent internal pressure buildup and cell damage. The module has a housing with multiple cells and through holes connecting them to the outside. A duct cover seals the cell exhaust openings. The cover has discrete protrusions facing the cell-free areas of the housing. This allows gas to escape through the holes when cells vent, preventing blockage by the duct cover collapsing. The protrusions stop gas flow from other cells. This ensures venting even if the cover is deformed from impact.

13. Battery Pack with Directional Cell Arrangement and Integrated Cooling System

LG ENERGY SOLUTION LTD, 2025

Battery pack design for electric vehicles that improves energy density, mechanical rigidity, and space utilization compared to conventional packs. The pack has a unique arrangement of battery modules inside a case. Each module has battery cells arranged in one direction, enclosed in a case with beams between the cells. The modules are fixed to the cover of the pack instead of a separate tray. This eliminates gaps, beams, and covers inside the pack. Cooling is integrated into the module base plate. The pack cover has a water channel to circulate cooling fluid around the modules. This reduces heat transfer path, parts, and space compared to separate heatsinks.

US12294071B2-patent-drawing

14. Electric Vehicle Battery Pack Thermal Management System with Flexible Tube Network and Manifold Design for Direct Contact Cooling/Heating

DELTA COSWORTH LTD, 2025

Thermal management system for electric vehicle battery packs that provides efficient cooling and heating without adding significant weight or cost. The system uses a network of flexible tubes connecting intake and exhaust manifolds with channels tuned for even fluid flow distribution. It allows direct contact cooling/heating of individual battery cells by conforming tubes passing between them. The system connects to a pump and heat exchanger for circulating fluid through the pack. The flexible tubes fill and bleed easily for installation. The manifold design prevents fluid bypassing and ensures full inflation.

US12294072B2-patent-drawing

15. The Overlooked Role of Battery Cell Relaxation: How Reversible Effects Manipulate Accelerated Aging Characterization

markus schreiber, theodore s steiner, jonas kayl - Multidisciplinary Digital Publishing Institute, 2025

Aging experiments are pivotal for car manufacturers to ensure the reliability of their battery cells. However, realistic aging methods time-consuming and resource-intensive, necessitating accelerated techniques. While these techniques reduce testing time, they can also lead distorted results due partially reversible nature cell behavior, which stems from inhomogenization rehomogenization conducting salt lithium distribution in electrode. To accurately capture phenomena, relaxation must be incorporated into test design. This work investigates impact procedure several stress factors, namely depth discharge C- rate, on formation inhomogeneities. The experimental reveal increasing inhomogenization, leading growing capacity losses, particularly under conditions with shorter cycling interruptions (check ups rest phases). These losses associated a significant reduction cycle life performance up 400 identical but interruptions. Similar trends observed depths C-rates. Optimized recovery cycles effectively mitigate doubling stability without requiring considerable additional time. Furthermore,... Read More

16. Composite Positive Electrode Material with Porous Conductive Matrix and Electronic Conductor Coating for All-Solid-State Lithium Batteries

NISSAN MOTOR CO LTD, 2025

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.

US2025125337A1-patent-drawing

17. Battery Charging System with Dynamic Temperature Control Based on Power Source Output Comparison

TOYOTA JIDOSHA KABUSHIKI KAISHA, 2025

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.

18. Secondary Battery with Fiberized Binder in Positive Electrode and Granular Active Material in Negative Electrode

LG ENERGY SOLUTION LTD, 2025

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.

19. Battery Module with Integrated Dual-Phase Change Material Thermal Management System

INZICONTROLS CO LTD, 2025

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.

US2025125437A1-patent-drawing

20. Electric Vehicle Power Supply with Alternating Power Cards and Link Capacitors for Enhanced Cooling and Ripple Current Absorption

FORD GLOBAL TECHNOLOGIES LLC, 2025

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.

US2025125757A1-patent-drawing

21. Battery Voltage Abnormality Diagnosis Using Temporal Discrepancies Between Measured and Estimated Open Circuit Voltage Data

22. Lithium-Ion Battery Degradation Diagnosis via Resistance Measurement During Charging

23. Electric Vehicle Dashboard with Integrated Battery Degradation and Charge Display System

24. Energy and Thermal Management System with Predictive Cooling for Fuel Cell Vehicles

25. Secondary Battery with Magnetically Controlled Multi-Layer Safety Vent System

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