Techniques for Faster Charging of EV Batteries

Enabling efficient and convenient battery swapping for electric vehicles to enable longer range and faster charging compared to battery charging. The method involves using vehicles themselves to transfer batteries between each other in a peer-to-peer fashion. When a vehicle's battery needs charging, it finds another nearby vehicle with a fully charged battery using onboard sensors and communication. The vehicles then physically connect and swap batteries. This allows a vehicle to quickly obtain a fully charged battery instead of waiting for its own battery to charge. The swapped battery can then be returned to the original vehicle for future use. This peer-to-peer battery swapping leverages the mobility of vehicles themselves to facilitate rapid and convenient battery swapping.

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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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System and control methodology for heating and charging battery packs using AC power, enabling rapid and efficient thermal management. The system integrates AC power delivery with a temperature-controlled heating circuit, where the heating element is controlled by a temperature sensor. The charging circuit includes rectifier switches, a transformer, and a series switch. During charging, the charging circuit injects AC current into the battery through the series switch, while the heating circuit injects DC current through a transformer and series switch. This synchronized operation ensures uniform heat distribution across the battery pack.

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A charging system and charger for lithium-ion batteries that optimizes charging duration while preventing over-discharging. The system employs real-time monitoring of battery state parameters including lithium precipitation levels, internal resistance, and temperature to dynamically adjust charging rates. This enables precise control over charging conditions to prevent over-discharging while maintaining optimal charging performance. The charger incorporates an integrated monitoring system that continuously tracks battery health indicators, enabling early detection of potential issues before charging begins.

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Self-supported, porous, 3D, flexible host anode with lithiophilic constituents for lithium-metal secondary batteries that enables fast charging, high cycling stability, and high energy density. The anode has a porosity of at least 70%, thickness between 10-100 μm, and fibers with diameters of 200 nm-40 μm. It contains a primary lithiophilic constituent with dendritic morphology, along with small amounts of additional lithiophilic materials. The open porosity allows rapid lithium intercalation/deintercalation, preventing dendrite formation and mossy lithium. The fibrous structure enables fast diffusion of lithium ions and reduces polarization. The self-supported design eliminates the need for a current collector fo

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An anode material for lithium-ion batteries that combines enhanced lithium ion intercalation sites with superior electrochemical performance. The material achieves improved charge/discharge characteristics through optimized pore structure and surface properties. The material's pore volume, specific surface area, and oil absorption value are precisely controlled within a specific range, ensuring sufficient reaction sites and electrochemical pathways for efficient lithium ion intercalation. This enables enhanced rate performance compared to conventional anode materials, while maintaining stable cycling characteristics.

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Electrode for batteries that enhances rate performance through optimized electrode architecture. The electrode comprises a lower layer with reduced binder content, where graphite particles are oriented in the surface direction, and a higher layer with enhanced binder content. The lower layer achieves sufficient ion diffusion through its smaller particle size and lower binder content, while the higher layer utilizes its higher binder content to maintain orientation and enhance ion transport. The optimized architecture minimizes particle breakage during press formation, maintaining a consistent reaction area and maintaining orientation.

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Electric vehicle onboard charger system that prevents voltage and current fluctuations during high power demand. The charger uses H-bridge circuits and resonant circuits to stabilize voltage and current. It has two H-bridges connected by a transformer. Each H-bridge has four switches. One H-bridge connects to the battery and converts DC to higher voltage. The other H-bridge connects to the input AC or output DC. Resonant circuits between the midpoints of the H-bridges help stabilize voltage and current. This prevents brownouts and instability during high power demand.

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Water-dispersible, self-conductive electrode matrices for Li-ion batteries made by synthesizing conducting polymer composites in situ with polyanionic binders. The composites are composed of electrically conductive polymers like polypyrrole (PPy) and polyanionic binders like carboxymethyl cellulose (CMC) dispersed in water. These composites replace traditional carbon additives and binders in battery electrodes. The PPy:CMC composites provide electrical conductivity, adhesion, and charge storage. The composites enable carbon-free cathodes to cycle at high rates without added carbon. The composites can also activate during charging to further increase conductivity.

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A charging system for electric vehicles with higher voltage traction batteries, enabling efficient charging through a novel configuration. The system comprises a battery pack with two series-connected groups of battery cells, a high-voltage terminal directly connected to the first group, a low-voltage terminal connected to the second group, and an inverter coupled to both the battery pack and the electric machine. This configuration allows the high-voltage terminal to be directly connected to the battery pack, while the low-voltage terminal is connected to the electric machine. The inverter handles the power flow between these terminals, enabling efficient charging of the higher voltage battery pack through the lower voltage system.

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Safety-enhanced charging ports for electric agricultural work vehicles like tractors that enable both DC Fast Charging and AC grid power charging. The charging ports feature a unique configuration where DC charging ports are positioned above the battery pack, with a fixed cover that connects to a separate DC charging unit. The cover's hinge design allows the DC charging ports to be positioned at an optimal distance from the battery pack, ensuring safe charging while maintaining optimal charging efficiency. The charging ports are positioned in front of the battery pack, with a cover that protects the DC charging ports from the battery's electrical field.

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Tabless secondary battery design to reduce internal resistance and enable fast charging without localized current concentration. The battery has an electrode wound body with tapes covering the side surfaces. One tape covers the side near the positive end, another covers the side near the negative end, and a third tape covers the middle section. The tape elongation percentages are chosen such that the middle section tape can accommodate expansion without high stress concentrations. This prevents current density variations due to electrode expansion/contraction during charging/discharging.

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Switching circuit design for DC fast chargers used to charge electric vehicle batteries. The circuit uses MOSFET switches arranged in a matrix converter configuration. The MOSFETs have body diodes that allow bidirectional current flow when the MOSFET is on. However, when the MOSFET is off, the body diodes block current in both directions to prevent reverse current through the adjacent MOSFETs. This allows bidirectional current flow through the matrix converter while preventing reverse current between adjacent MOSFETs when they are turned off.

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Battery design for solid-state batteries with improved charging speed and stability. The design involves using a specific pattern of domed notches on the cathode and anode plates, with corresponding protrusions in the solid electrolyte that fit into the notches. This creates a 3D interconnected structure between the electrodes and electrolyte that reduces Li ion diffusion pathlengths compared to flat interfaces. It allows faster charging without issues like Li plating due to more uniform current density distribution and mechanical stability of the interconnected structure.

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Negative electrode active material for rechargeable lithium batteries that enhances rapid charging capabilities. The material comprises a carbon-based core with vanadium oxide on its surface and a fluorine-containing carbon layer on its surface. This composition enables efficient lithium-ion intercalation during high-rate charging while maintaining the negative electrode's stability and safety.

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A solid electrolyte for all solid-state batteries that improves cycle life and fast charging performance. The electrolyte contains a combination of argyrodite-type compound, sulfur compound, and iodine compound. This electrolyte composition reduces lithium plating during charging and suppresses electrode swelling and cracking during cycling compared to using just argyrodite. The all solid-state battery using this electrolyte has improved cycle life and fast charge capability.

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Electric vehicle charging ports configuration to allow charging from both DC fast chargers and AC mains power while preventing cable clashes. The ports are located on the front of the vehicle with a cover that has a hinged movable section between adjacent ports. The hinge allows wider spacing between the DC ports compared to the AC port, preventing cable crossover when both are in use. This enables simultaneous access to both DC and AC charging sources. The hinged cover also protects the ports when not in use.

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Simultaneously charging multiple thermal batteries in transportation vehicles without large industrial chillers. The system uses a central thermal storage reservoir connected to the charging circuits of the vehicle batteries. An industrial chiller recharges the storage reservoir over an extended time. This allows simultaneous fast charging of the vehicle batteries using the pre-chilled storage reservoir instead of external chillers.

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Multi-voltage storage system for electric vehicles that enables high charging voltages like 800V while still supporting 400V loads. The system has multiple identical energy storage modules connected in series for charging at high voltage, and a switching unit to connect/disconnect the modules in parallel for driving at low voltage. This allows using 400V modules for loads and charging at 400V, while connecting the modules in series for 800V charging. A control unit coordinates the switching between configurations. This provides flexibility to handle both 400V and 800V without needing dedicated 800V modules.

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Workload-dependent load-sharing mechanism for multi-battery systems that balances battery aging, maximizes power delivery, and optimizes charging sequences. The mechanism uses switches and logic to dynamically connect the batteries in parallel, series, or individually based on factors like state of charge, load demand, and battery type. This allows balancing charge cycles, providing turbo power when needed, and optimizing charging sequences for hybrid batteries with fast charging and high energy density.

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