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The long charge time of electric vehicles compared with the refueling time ofgasoline vehicles, has been a major barrier to the mass adoption of EVs.Currently, the charge time to 80% state of charge in electric vehicles such asTesla with fast charging capabilities is >30 minutes. For a comparablerecharging experience as gasoline vehicles, governments and automobilecompanies have set <15 min with 500 cycles as the goal for extreme fastcharging (XFC) of electric vehicles. One of the biggest challenges to enableXFC for lithium-ion batteries (LIBs) is to avoid lithium plating. Althoughsignificant research is taking place to enable XFC, no promisingtechnology/strategy has still emerged for mainstream commercial LIBs. Here, wepropose a thermally modulated charging protocol (TMCP) by active thermalswitching for XFC, i.e., retaining the battery heat during XFC with the switchOFF for boosting the kinetics to avoid lithium plating while dissipating theheat after XFC with the switch ON for reducing side reactions. Our proposedTMCP strategy enables XFC of commercial high-energy-density LIBs with chargetime <15 min and >500 cycles while simultaneously beating other targets set byUS Department of energy (discharge energy density > 180 Wh/kg and capacity loss< 4.5%). Further, we develop a thermal switch based on shape memory alloy anddemonstrate the feasibility of integrating our TMCP in commercial batterythermal management system.

Extreme fast charging of batteries using thermal switching and self-heating