Battery Charging and Discharging Optimization for EV

Adaptive battery management for extending the life of high-voltage battery packs in electric vehicles by automatically adjusting charging and discharging limits based on cell condition data. The method involves measuring cell voltage, current, and temperature, processing the data through calibrated relationships to determine cell degradation values, and then modifying charge/discharge limits and thermal limits based on those values. This allows operating the battery at lower limits when cells are degrading to delay failure and extend overall pack life.

Source

A system to prevent battery damage during charging by measuring battery temperature and controlling charge/discharge power. The system includes a temperature sensor in the battery to monitor temperature during charging. A battery management system (BMS) receives the temperature data and adjusts the charge/discharge power to prevent overheating and damage. This allows proactive cooling and protection of the battery during charging based on real-time temperature feedback.

Source

A vehicle battery system that can prevent damage from overcharging and cell failures. The system has an overcharge limit device that individually disconnects cells with high pressure. When a cell is disconnected, the controller stops controlling that cell and continues operating the rest. This prevents further overcharging. If multiple cells are disconnected, it stops all cells. This prevents overcharging of remaining cells. It also excludes disconnected cells from balancing and lowers the overall battery output limit.

Source

Electrified vehicle with a battery that can be power limited based on the thermal exchange capacity of the coolant fluid circulated by the thermal management system. The power limit is gradually reduced at higher battery temperatures to prevent sudden power interruptions. The limit lines increasing in steepness in correlation with thermal exchange capacity allow higher charge/discharge rates when the coolant temperature is lower. This balances battery performance and temperature management without unnecessary power limits.

Source

Reducing battery swelling and degradation during charging by actively cooling the battery cell when it reaches full charge and high temperature. A thermoelectric cooler (TEC) is used to cool the battery cell when the state of charge (SOC) exceeds a threshold and the temperature exceeds a threshold. This prevents excessive heating and swelling during float or trickle charging, which can degrade battery life. The cooling is activated by the battery management system (BMS) controller based on SOC and temperature sensors.

Source

Fast charging of rechargeable batteries like lithium-ion cells without degradation or safety issues at low temperatures by preheating the battery internally using a heat spreader. The spreader is inserted partially or fully inside the battery cell and conducts heat from an external source to warm the cell before charging. This avoids the dangers of high current densities and lithium plating at cold temperatures. The spreader can contact the electrode terminals or be inside the cell housing. It enables rapid charging at temperatures like room temperature, which reduces time compared to waiting for internal heating during charging at low temperatures.

Source

Controlling thermal runaway propagation in battery packs with multiple modules by selectively discharging modules to prevent runaway spread. When a thermal runaway is detected in one module, the controller checks if current is flowing through that module. If not, it decouples the module to isolate the runaway. If current is flowing, it connects the other modules to an external load to discharge them, preventing runaway propagation. This controlled discharge can mitigate thermal runaway chain reactions in battery packs.

Source

Vehicle battery module with independent temperature control for each battery cell to prevent temperature variations between cells. The module has a heat transfer system with a heater, pipes, and a flow rate controller. A temperature sensor monitors each cell. The controller adjusts the heated fluid flow rate based on cell temperatures. It prioritizes heated fluid to low temperature cells. This prevents overheating or undercooling issues that can degrade battery performance or life.

Source

Charging inlet for electric vehicles that allows higher charging rates without risk of damaging the charging system due to heat. The charging inlet has a flexible thermal sensor mounted directly on the power terminal that curves along the terminal's outer surface. This allows more accurate and faster temperature monitoring compared to sensors farther away. It prevents overheating by enabling faster response to high temperatures and reducing the power transfer rate if needed. The sensor's flexibility conforms to the terminal shape for better contact.

Source

Optimizing battery charging and discharging to improve performance and longevity by regulating battery temperature based on charging location and anticipated charge/discharge conditions. The method involves identifying the charging location, determining if excess charge is available, and cooling the battery pack using that excess charge instead of charging at full rate. It also sets target temperatures based on charging location to prevent overheating in hot environments and overcooling in cold environments.

Source

Battery thermal management system for electric vehicles that uses a selectively activated thermoelectric device to augment cooling of the battery pack during high thermal load events like DC fast charging. The thermoelectric device is positioned in the coolant circuit and powered separately from the battery during charging to draw heat from the coolant and further cool the battery. This prevents overheating during intense charging when the battery demands more power. The thermoelectric cooling is also activated if ambient temperatures exceed a threshold.

Source

Safe charging of electric vehicles (EVs) using a thermal monitoring and circuit management feature in the charging connector itself. The connector has embedded thermal sensors that can detect overheating. If a predetermined threshold temperature is exceeded, the connector disrupts the charging control signal to the EV. This stops charging until the temperature drops. The connector can also reverse the charging polarity to allow the EVSE to detect thermal faults. The onboard thermal management prevents overheating issues without requiring additional wiring back to the EVSE.

Source

Optimizing the performance of lithium-ion battery systems in electric vehicles by actively cooling them during charging and discharging. The method involves using a cooling system with a heat exchanger in each battery module. The system monitors the temperature of the modules and cells during charging/discharging. If the temperature exceeds a threshold, it reduces the charging/discharging current. This prevents overheating beyond the optimal temperature range for the cells. By actively managing cell temperatures, it allows higher charging/discharging rates without degradation.

Source

Battery cell design to improve cycle life and safety by controlling temperature inside the cell. The cell has a plate shape with sealing parts around the edges that fuse together. The sealing parts have bent sections that closely contact the cell body. Phase change material (PCM) is coated on the inner bent surfaces. The PCM absorbs/releases heat to maintain stable cell temperature during charging/discharging. This prevents excessive temperature variations and mitigates internal damage. The bent sealing configuration maximizes PCM contact area.

Source

Optimizing temperature control in electric vehicle batteries during fast charging to prevent degradation and improve lifetime. The method involves simulating battery responses at different charge rates and temperatures to find an optimal input temperature profile that minimizes lithium plating and uniformly heats/cools the battery. This profile is then applied to the temperature management system to optimize charging without uneven heating/cooling. By accurately modeling and optimizing battery temperature profiles, lithium plating can be reduced during fast charging.

Source

Adjusting the charging condition of a secondary battery to prevent overheating when cooling is not practical. The method involves predicting the temperature rise of the battery during charging based on its current temperature, current, and external conditions. If the predicted charging voltage is lower than the upper limit, it is lowered to match. This prevents excessive charging currents that raise temperature. By dynamically adjusting the charging limit based on prediction, it prevents overheating even without active cooling.

Source

Battery thermal management system and charging/discharging control method for electric vehicles that improves battery life and safety by optimizing charging/discharging currents based on battery temperature, temperature rise, and internal resistance. The system uses a microcontroller (MCU) and temperature sensors to monitor battery conditions during charging and discharging. It adjusts current limits, balances charge/discharge, and regulates cooling to prevent overheating, smoldering, leaking, short circuiting, fires, and explosions.

Source

A thermal management system for power batteries that effectively controls battery temperature to improve battery life and safety. The system has a temperature sensor, controller, cooling source, charging module, and discharge module. The charging module has two current stages, with the second stage having lower current. Batteries, the temperature sensor, and both modules connect to the system. This allows targeted cooling based on sensor readings during charging and discharging to prevent overheating and minimize temperature extremes.

Source

Controlling battery degradation rate in electric vehicles by adjusting charging/discharging power to equalize temperature and deterioration across batteries. A power exchange controller monitors battery temperatures during charging/discharging and adjusts power flow to maintain an equalized temperature. This prevents faster degradation in hotter batteries by throttling their charge/discharge rate. By matching degradation rates across batteries, it aims to extend overall battery life.

Source

A lightweight, high-performance battery with regulated output voltage, cell balancing, and self-monitoring diagnostics to prevent thermal runaway. The battery has separate charging and output connections, allowing higher charging voltages. A microprocessor-controlled MOSFET switching circuit monitors cells, balances voltage, prevents overcharge/discharge, and isolates faulty cells. The output voltage is adjustable. A polling circuit disconnects cells to measure voltage and isolate faulty ones. The battery also has a microprocessor, display, and charging circuitry.

Source

A battery pack design for electric vehicles that improves battery life by controlling and limiting heating during charging and discharging to prevent degradation. The pack uses a unique cell-to-cell interconnection method involving copper tabs that not only provide electrical connection but also serve as heat sinks to draw heat away from the cells. This helps maintain consistent cell temperatures during charging/discharging to extend battery life. The tabs are sized to balance conductivity and mechanical integrity, rather than just minimum conductivity, to prevent ripping or breaking. The pack also uses a stack configuration with coextensive cell perimeters.

Source

Battery module and battery design for high power density applications like electric vehicles that enables long life and discharge autonomy without requiring external charging. The battery module has internal charging management circuitry that allows charging from an external source while maintaining the cells at optimal operating temperature. The charging circuit has separate terminals for charging vs. use, with a temperature sensor and heater. When connected to an external charger, the charging circuit controls the charge rate and termination based on the temperature. This prevents overcharging at low temperatures that can damage the cells. The battery pack has multiple modules in series connected to external use terminals. Charging the pack involves connecting to the charging terminals instead. This allows charging without disturbing the use terminals. The charging circuit can also send a quantitative charging setpoint to the charger to coordinate charging rates.

Source

Battery charge/discharge control system for secondary batteries in hybrid vehicles that prevents overcharging and overdischarging to extend battery life. The system estimates the internal battery state using a dynamic battery model with appropriate boundary conditions. It calculates a battery state estimation based on sensor readings and generates battery information for charge/discharge restrictions. This prevents excessive charging/discharging that can degrade battery performance. The system uses models for electrochemical reactions, concentration diffusion, and potential distribution in the battery electrodes and electrolyte. The boundary condition at the electrode-electrolyte interface is set based on a relation between concentration time derivative and reaction current.

Source

Power supply system for electric vehicles with multiple battery packs that allows simultaneous temperature management and power delivery. The system uses separate charge/discharge controllers for each battery pack. To manage the temperature of a critical pack, it determines if heating or cooling is needed based on pack temperature. For heating, it restricts current to prevent overvoltage. For cooling, it determines an optimal current to balance resistive heat generation with entropy change cooling. This allows efficient temperature control while still meeting power requests. The other packs can flexibly charge/discharge.

Source

Battery pack design and operating method to prevent damage to individual cells in a pack without external compensation electronics. The pack has cells with positive and negative poles on their end faces, electrically connected in series/parallel. This allows monitoring and charging each cell individually without separate connections. It prevents overcharging/discharging by checking each cell's voltage against limits. If a cell reaches upper/lower limit, it's compensated internally without external electronics. This avoids the need for separate cell connections and external compensation electronics, simplifying pack fabrication and preventing failures from broken cables or detached contacts.

Source

Optimizing the life and performance of hybrid and electric vehicle energy storage systems (ESS) by using customized charging, discharging, and redistribution techniques that consider factors like state of charge reset, thermal models, variations in storage technologies, end-of-life status, and cycle life differences between banks. The technique involves allocating charging and discharging power based on remaining cycle life, performing equalization during active operation, adjusting operating parameters as cycle life accumulates, and using estimated temperatures instead of actual measurements.

Source

Method for extending the life and performance of hybrid and electric vehicle energy storage systems (ESS) by utilizing customized charging, discharging and redistribution techniques that depend upon factors like state of charge reset calculations, thermal models, variations in storage technology, end-of-life status, and variations in life cycle between banks. It also involves allocating charging and discharging power based on remaining cycle life to avoid prematurely degrading certain banks. The technique includes techniques like equalizing SOC between banks during quiescent periods, adjusting parameters based on temperature models, reducing operating ranges as usage accumulates, and apportioning power based on cycle life.

Source