Fast charging of electric vehicle batteries involves managing significant power flows—often exceeding 350kW—while maintaining cell stability across varying states of charge and temperature conditions. Current systems face limitations in charging speed due to thermal constraints, with most commercial vehicles restricted to charging rates that require 20-30 minutes to reach 80% capacity from a depleted state.

The fundamental challenge lies in maximizing charge transfer rates while preventing degradation mechanisms that occur at high current densities and elevated temperatures.

This page brings together solutions from recent research—including dynamic current control systems, temperature-optimized charging protocols, liquid-cooled charging infrastructure, and adaptive multi-phase charging strategies. These and other approaches aim to reduce charging times while preserving battery longevity and safety across real-world operating conditions.

1. Rechargeable Battery Cells with High Capacity Si-C Composite Anodes and Porous Separators for Rapid Li-ion Transport

STOREDOT LTD, 2025

Rechargeable battery cells with parameters designed to achieve extreme fast charging and extreme energy density properties. The cells have anodes with high areal capacity coatings like Si-C composites, cathodes with lower areal capacity, separators with high porosity, and electrolytes capable of fast Li-ion transport. This configuration allows rapid charging (>70% in 10 mins) without compromising performance or lifespan. The optimized anode-cathode balance, separator properties, and electrolyte characteristics enable sequential charging/discharging with high capacity loading in minutes.

US12374759B2-patent-drawing

2. Controller for DC Fast Charging Power Conversion Units with Input and Output Voltage-Based Control Signal Generation

RIVIAN IP HOLDINGS LLC, 2025

Controller for DC fast charging power conversion units like those found in electric vehicle charging stations. The controller improves the performance of the DC-DC converter in a charging station by generating control signals based on the input voltage and output voltage of the converter. This allows the converter to better adapt to varying load and battery conditions compared to just using input voltage alone.

3. Electric Vehicle Thermal Management System with Throttled Refrigerant Flow and Integrated Valve Seat

BYD COMPANY LTD, 2025

Thermal management system for electric vehicles that enables efficient cooling of the battery pack during fast charging to prevent overheating. The system uses a compressor, external heat exchanger, throttle valve group, and two heat exchange plates. It operates in a battery cooling mode where a throttled, depressurized refrigerant flows through one or both heat exchange plates to cool the battery pack. This ensures the battery module can dissipate heat generated during charging in a timely manner. It also integrates the throttle valve group on a valve seat to save space. The system can further switch between cooling modes using a valve to optimize cooling performance.

4. Electric Vehicle Charging Cable with Multi-Tube Liquid Cooling System

SOUTHWIRE COMPANY LLC, 2025

Liquid cooled charging cable for electric vehicles that enables higher charging currents without excessive heat buildup. The cable has multiple coolant supply tubes surrounding the conductors, a return tube, and a jacket. The coolant circulates through the tubes to cool the conductors and handle. This reduces thermal resistance and allows higher current densities compared to air cooled cables. The liquid cooling also helps prevent excessive temperatures on the charging handle.

5. Battery Preconditioning System with Journey-Based Temperature Control for Electric Vehicle Charging

BAYERISCHE MOTOREN WERKE AG, 2025

Optimizing battery charging of electric vehicles by preconditioning the battery during the journey to a rapid charging station. The battery temperature is controlled from the start of the journey to reach a specific temperature at the charging station. This involves heating the battery during the trip using techniques like trimming the motor efficiency or battery heating systems. By estimating power loss and environmental factors, it predicts the battery temperature without preconditioning. This allows determining if preconditioning is necessary.

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6. Secondary Battery Negative Electrode with Double Coating Structure of Graphite Outer Layer and Silicon-Containing Inner Layer

CONTEMPORARY AMPEREX TECHNOLOGY LTD, 2025

Secondary battery with improved fast charging and cycle life by using a double coating structure on the negative electrode plate. The negative electrode has an outer coating with graphite and a silicon-containing inner coating. The outer coating includes graphite only, while the inner coating has artificial graphite and silicon. The silicon content in the inner coating (W2) is greater than or equal to the silicon content in the outer coating (W1). This double coating structure allows better electrolyte infiltration and backflow, reducing ion precipitation and improving fast charging and cycle performance.

7. Electric Vehicle Thermal Management System with Separate Refrigerant and Coolant Loops for Integrated Cabin and Battery Temperature Control

HANON SYSTEMS, 2025

Vehicle thermal management system for electric vehicles that provides efficient cooling, heating, and battery temperature control. The system uses separate refrigerant and coolant loops to cool the cabin, components, battery, and charge rapidly. It integrates refrigerant components like compressor, condenser, and chiller with a coolant loop through the cabin, radiator, battery, and components. A valve allows selective coolant flow through the chiller and battery. This allows simultaneous cabin and battery cooling, separate battery cooling, and battery heat absorption modes. The refrigerant loop only absorbs heat from air and components. The coolant loop provides independent cooling, heating, and dehumidification. It also enables battery rapid charging without refrigerant. The system reduces compressor power, complexity, and cost compared to direct heat pump systems.

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8. Charging System with Temperature-Responsive Power Adjustment Mechanism

ON-BRIGHT ELECTRONICS CO LTD, 2025

Adaptive power management for charging systems to mitigate overheating and improve battery life during fast charging. The charging system adjusts input and output power based on device temperature. If the temperature exceeds a threshold, it decreases input/output power when temperature rises and increases when temperature drops. This helps prevent overheating during fast charging.

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9. Dual Converter Architecture for Battery Charging with Series-Connected Inductive and Capacitive Switching Converters

RICHTEK TECHNOLOGY CORP, 2025

High efficiency charging system for batteries using a dual converter architecture. The system has two switching power converters, an inductive and a capacitive one, connected in series. The converters operate in different modes based on the input DC power to optimize efficiency and performance. The inductive converter regulates the DC power or bypasses it directly. The capacitive converter regulates the charging power or bypasses it. The converters are selectively controlled based on DC voltage to balance efficiency and power capacity. This allows efficient charging at low input voltages, high charging currents, and maximum efficiency points.

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10. Electric Vehicle Charging Network with Inter-Station Power Sharing Mechanism

SK SIGNET INC, 2025

Rapidly charging electric vehicles by sharing power between charging stations when one station is idle. The system allows multiple charging stations in a network to share power with each other to charge vehicles faster. When a vehicle requests charging, the system checks the occupancy of nearby stations. If a neighboring station is idle, power is shared with that station to provide additional charging capacity. This allows charging stations to pool their power resources to rapidly charge vehicles even if their individual capacity is less than the vehicle's maximum.

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11. Optimised Centralised Charging of Electric Vehicles Along Motorways

ekaterina dudkina, claudio scarpelli, valerio apicella - Multidisciplinary Digital Publishing Institute, 2025

Nowadays, when battery-powered electric vehicles (EVs) travel along motorways, their drivers decide where to recharge cars batteries with no or scarce information on the occupancy status of next charging stations. While this may still be acceptable in most countries, due limited number EVs long queues build-up coming years increased mobility, unless smart allocation strategies are designed and implemented. For instance, as we shall investigate manuscript, a centralised coordination individual has potential significantly reduce queuing time at In particular, paper explain how problem motorways can modelled an optimisation problem, propose some based dynamic solve it, implemented practice using charge manager that exchanges solves problems. Finally, compare realistic scenario current decentralised recharging one, show that, under simplifying assumptions, queueing times reduced by more than 50%. Such significant reduction allows one greatly improve vehicular flows general journey durations without requiring building new infrastructure. Reducing positive impact traffic congestion emis... Read More

12. Optimal Energy Management in PV-Powered Switched Reluctance Motor Based Electric Vehicles

srinivasa rao jalluri, naga swetha b, b harshini - Integrated Publishing Association, 2025

This paper incorporates a PV module, boost converter, bidirectional an Incremental Conductance (INC) Maximum Power Point Tracking (MPPT) algorithm and Proportional-Integral (PI) controller for optimal energy management in Electric vehicle operation. The analysis evaluates efficiency, dynamic response power under varying irradiance conditions. simulation results reveal that the module attains peak efficiency (99.35% 99.9%), ensuring effective conversion while SRM drive, supported by PI controller, maintains stable precise converter facilitates seamless battery charging discharging, enhancing utilization supporting regenerative braking. Battery performance shows voltage with adaptive current adjustments though State of Charge declines reduced output reflecting load compensation. research underscores systems consistency, optimum cost aptness sustainable EV utilizations, representing robust motor control attainment. study highlights potential motor-based PV-powered EVs effectual ecological transportation solutions.

13. Battery with Nitrile-Containing Solvent, Oxidizing Gas, and Metal Halide Cathode

INTERNATIONAL BUSINESS MACHINES CORP, 2025

A battery design with a unique electrolyte composition to improve charging rates, energy efficiency, power density, cyclability, and cost compared to traditional batteries. The battery uses a nitrile-containing solvent, an oxidizing gas, and a metal halide as the active cathode material. The nitrile solvent stabilizes the electrolyte and prevents electrolyte decomposition. The oxidizing gas provides oxygen for cathode reactions. The metal halide functions as the cathode material. This electrolyte formulation enables fast charging, high efficiency, high power density, and good cyclability.

14. Battery Cell with Breathable Casing and Optimized Electrolyte Conductivity for Enhanced Gas Management

CONTEMPORARY AMPEREX TECHNOLOGY LTD, 2025

Battery cell design with improved charging speed while balancing life by optimizing gas containment, electrolyte conductivity, and ventilation. The battery cell has a casing with a breathable component that discharges gas when pressure reaches a threshold. The cell also has an electrolyte with specific conductivity and remaining volume ratio to balance charging capability and gas containment. This allows fast charging without excessive gas generation while preventing premature capacity fade.

15. Lithium-Ion Battery Quick Charging Protocol via Internal Resistance Profile Analysis in Two-Electrode Cells

LG ENERGY SOLUTION LTD, 2025

Establishing a quick charging protocol for lithium-ion batteries without needing a three-electrode cell. The method involves determining the charging limit for each current rate by analyzing internal resistance profiles. The procedure is: (a) charge a two-electrode battery cell at multiple currents to get open circuit voltages vs. SOC, (b) charge at higher currents vs. SOC, (c) map charging limits based on lowest internal resistance vs. SOC. This method reflects resistance and heating of large capacity cells vs. current vs. SOC.

16. Electric Vehicle Charging Station Site

r yashoda - MGM Publishing House, 2025

Abstract: With the rapid adoption of electric vehicles (EVs) worldwide, demand for efficient and accessible charging infrastructure has become increasingly significant. Electric Vehicle Charging Station Sites (EVCSS) play a crucial role in supporting widespread deployment usability EVs. This introduction abstract provides concise overview key aspects considerations surrounding establishment EVCSS. The begins by highlighting exponential growth vehicle market consequent need reliable network. It explores various types stations, including slow charging, fast ultra-fast each catering to different requirements time constraints. Moreover, delves into importance strategically locating stations maximize convenience EV owners, such as near residential areas, commercial centers, major transportation hubs. Furthermore, addresses critical elements that contribute an effective EVCSS design. emphasizes significance scalability accommodate projected increase adoption, ensuring availability all users. integration renewable energy sources, solar panels or wind turbines, is also highlighted sustainabl... Read More

17. A Spatiotemporal analysis of photovoltaic electricity storage potential in electric vehicles

noemie jeannin, jeremy dumoulin, alejandro penabello - Aalborg University Press, 2025

Decarbonizing mobility and integrating more renewable sources in electricity production are necessary levers to meet the climate targets. Coupling electric vehicle (EV) charging with photovoltaic (PV) generation could help provide clean for EVs flexibility storage PV installations. The batteries of vehicles can then be discharged into grid support supply during periods high demand. This study uses a GIS-based methodology analyse needs European population estimates an electrified fleet. Charging scenarios applied distribute between home, work, point interest quantify demand both space by hectare time hour. load curves compared typical estimate amount that stored locally EVs. Considering two (comfort flexible charging) spatio-temporal was three cities varying solar irradiance patterns: Aalborg (Denmark), Bern (Switzerland), Palermo (Italy). Results show 10% building footprint covered cover from 53% (in Alborg) 61% Bern) need over year. together reduce CO2 emission related private cars 17 28% 2035 current fuel-based

18. Electrode Alloy with Solid-Liquid Phase Composition for Enhanced Energy Density and Charge Rate in Electrochemical Devices

MASSACHUSETTS INSTITUTE OF TECHNOLOGY, CARNEGIE MELLON UNIVERSITY, 2025

Electrochemical devices with high energy density and fast charging capability by using alloys with both solid and liquid phases at normal temperatures. The alloy electrode can have mechanical softness to prevent dendrite growth while allowing high current density. The solid phase contains a first alkali metal like lithium and the liquid phase contains a different second alkali metal like sodium or potassium. This allows the alloy to have a solid phase for structure and a liquid phase for ion transfer.

US12322794B2-patent-drawing

19. Wireless Power Transfer for Electric Vehicles: A Review

abdul basit taj, yasir khan, hamza ahmad raza - Sukkur IBA University, 2025

Wireless Power Transfer (WPT) is an innovative and promising solution for charging Electric Vehicles (EVs) without physical connections. This review explores the advancements, challenges, methodologies associated with WPT technology, including its stationary dynamic capabilities. The paper examines key components such as inductive systems, compensation topologies, coil configurations, design considerations efficient power transfer. Emphasis placed on addressing challenges like misalignment tolerance, air gap efficiency, high-frequency operations. Emerging technologies, hybrid topologies infrastructures, are also discussed their potential to reduce battery size, improve environmental sustainability, increase EV adoption. Despite current limitations in cost ongoing research development aim optimize making them a viable alternative traditional plug-in methods.

20. Challenges and Issues Facing Ultrafast-Charging Lithium-Ion Batteries

amirreza aghili mehrizi, firoozeh yeganehdoust, anil kumar madikere raghunatha reddy - Multidisciplinary Digital Publishing Institute, 2025

Ultrafast-charging (UFC) technology for electric vehicles (EVs) and energy storage devices has brought with it an increase in demand lithium-ion batteries (LIBs). However, although they pose advantages driving range charging time, LIBs face several challenges such as mechanical degradation, lithium dendrite formation, electrolyte decomposition, concerns about thermal runaway safety. This review evaluates the key advances LIB components (anodes, cathodes, electrolytes, separators, binders), alongside innovations protocols safety concerns. Material-level solutions nanostructuring, doping, composite architectures are investigated to improve ion diffusion, conductivity, electrode stability. Electrolyte modifications, separator enhancements, binder optimizations discussed terms of their roles reducing high-rate degradation. Furthermore, addressed; adjustments can reduce electrochemical stress on LIBs, decreasing capacity fade while providing rapid charging. highlights technological advancements that enabling ultrafast assisting us overcoming severe limitations, paving way development next... Read More

21. Expansion Force‐Based Adaptive Multistage Constant Current Fast Charging with Lithium Plating Detection for Lithium‐Ion Batteries

22. Battery Charging System with Harmonic-Based Signal Shaping Circuit for Electric Vehicles

23. Lithium-Ion Battery Anode with Layered Porous Silicon and Metal Coatings Formed by Epitaxial Growth and Mechanical Thinning

24. Evolution of Fast Charging Systems and Their Impact on Electric Vehicle Adoption

25. Carbon-Composite Silicon-Based Nanostructures for Lithium-Ion Battery Anodes

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