Charging EVs 500% Faster Even in Subfreezing Temperatures

insightman

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A University of Michigan study describes a modified manufacturing process for Li-Ion batteries that can dramatically increase charging speed without adversely affecting battery life. The benefits of this process extend to charging in sub-freezing temperatures.

Currently, to prevent slow charging in cold temperatures, some EVs can pre-heat their batteries so they charge as quickly as in warm temperatures. But that pre-heating uses up battery power.

If battery resources were not expended to achieve faster charging, EVs would arrive at charging stations carrying a greater battery charge. That alone would reduce the time required to charge. However, this process also increases the charging speed.

The study was published in Joule, a monthly, peer-reviewed scientific journal that focuses on research and analysis related to sustainable energy solutions, bridging disciplines and scales of energy research.

Neil Dasgupta, corresponding author of the study, is a U-M Associate Professor for mechanical engineering and for materials science and engineering. He said, "We envision this approach as something that EV battery manufacturers could adopt without major changes to existing factories."

"For the first time, we’ve shown a pathway to simultaneously achieve extreme fast charging at low temperatures, without sacrificing the energy density of the lithium-ion battery."

Of course, most so-called "battery breakthroughs" never pan out, but I was reassured by the study appearing in a peer-reviewed journal and impressed the process didn't require major changes to existing factories. No magic anode elements or secret rare earths were required.

Full disclosure: I'm biased because I'm a Michigan Wolverine computer engineering graduate still living in Ann Arbor. If my MINI Cooper SE (110-mile EPA range) could achieve an 80% DC charge in 6 minutes instead of 30, long-distance trips would almost be feasible.
 
Found a link to the paper: https://www.cell.com/joule/abstract/S2542-4351(25)00062-5

Addressing the trilemma between fast-charging, low-temperature operation, and high-energy-density electrodes is critical to advance Li-ion batteries. Here, we introduce a strategy that integrates 3D electrode architectures with an artificial solid-electrolyte interface (SEI) using atomic layer deposition of a solid electrolyte (Li3BO3-Li2CO3). These synergistic modifications enhance both mass transport and interfacial kinetics under low temperatures and fast charging, increasing the accessible capacity of thick electrodes (>3 mAh/cm2). To decouple the contributions from electrolyte transport and interfacial impedance, graphite/LixNiyMnzCoaO (NMC) pouch cells were fabricated and their electrochemical performances were tested under low-temperature, fast-charging conditions. At a 6C-rate and a temperature of −10°C, these integrated electrodes enabled a >500% increase in accessible capacity and >97% capacity retention after 100 cycles, without Li plating. The capacity retention under low-temperature, fast-charging conditions was also dependent on the state-of-charge swing, highlighting the importance of the charging protocol to minimize Li plating.

The full paper appears to be $35. Although I would read it:
  • atomic layer deposition of a solid electrolyte
I typically associate this with vacuum chamber deposition. For R&D, good, but it may not scale for mass production.

Bob Wilson
 
Found a link to the paper: https://www.cell.com/joule/abstract/S2542-4351(25)00062-5

Addressing the trilemma between fast-charging, low-temperature operation, and high-energy-density electrodes is critical to advance Li-ion batteries. Here, we introduce a strategy that integrates 3D electrode architectures with an artificial solid-electrolyte interface (SEI) using atomic layer deposition of a solid electrolyte (Li3BO3-Li2CO3). These synergistic modifications enhance both mass transport and interfacial kinetics under low temperatures and fast charging, increasing the accessible capacity of thick electrodes (>3 mAh/cm2). To decouple the contributions from electrolyte transport and interfacial impedance, graphite/LixNiyMnzCoaO (NMC) pouch cells were fabricated and their electrochemical performances were tested under low-temperature, fast-charging conditions. At a 6C-rate and a temperature of −10°C, these integrated electrodes enabled a >500% increase in accessible capacity and >97% capacity retention after 100 cycles, without Li plating. The capacity retention under low-temperature, fast-charging conditions was also dependent on the state-of-charge swing, highlighting the importance of the charging protocol to minimize Li plating.

The full paper appears to be $35. Although I would read it:
  • atomic layer deposition of a solid electrolyte
I typically associate this with vacuum chamber deposition. For R&D, good, but it may not scale for mass production.

Bob Wilson
@bwilson4web, thanks for digging in and spotting a potential mass-production road-block not mentioned in U-M's press release. If, indeed, this technology can offer 500% faster charging without compromising battery longevity, it would provide an incentive to accept that slow vacuum-chamber step or to find ways to speed it up.

The link you found also offers 6 hours of HTML access to all articles for $4.
 
I'm still waiting for solid state batteries which were the big break-through 10 years ago. Now it seems like they will never happen as regular lithium batteries keep improving. Personally, with my I6, I don't really need any faster charging. On trips, where I stop every 3 or 4 hours for bio breaks, food, etc, it is usually finished charging before we get back to the car. Most of my charge times were 15 min or less. That is plenty fast enough for me.
 
I'm still waiting for solid state batteries which were the big break-through 10 years ago.
I wonder which always-10-years-out technology will commercialize first, solid-state batteries or nuclear fusion-based power plants?
 
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I've decided on home fusion power:
solar_top_only_panels.webp
  • ~6 kW - 16 solar panels x 400 W
  • 48 kW - grid (nuclear (42%), natural gas (31%), coal (14%)) if load exceeds 13.6 kWh battery stored energy
  • 16 kW - natural gas fueled generator in case grid goes down for extended period a week of wintery, cloudy weather
My home, primary load ranges from 0.2 to 9 kW. Single largest load, 7.4 kW EV car charging followed by cooking and hot water heater, ~1 kW each. On a sunny spring day with the rear door open and TV off, ~200 W.

Bob Wilson
 
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The primary reason for faster charging is lowering the required battery size.
If you can charge a 50 kw battery in 2 minutes, one does not need a 100kw battery.
less battery less weight higher efficiency.
As we all assume, most charging will be done slowly at home and other level 2 sources, but when you assume approaching 100 percent market penetration you need to do the math and long waits a chargers is not a good thing.
5 minute charging means people accepting a car with 150 miles of winter highway range because they can make it to aunt Martha's in the same time they used to
Smaller battery less resources to get the same job done.
 
The primary reason for faster charging is lowering the required battery size.
If you can charge a 50 kw battery in 2 minutes, one does not need a 100kw battery.
less battery less weight higher efficiency.
As we all assume, most charging will be done slowly at home and other level 2 sources, but when you assume approaching 100 percent market penetration you need to do the math and long waits a chargers is not a good thing.
5 minute charging means people accepting a car with 150 miles of winter highway range because they can make it to aunt Martha's in the same time they used to
Smaller battery less resources to get the same job done.
There is a trade off here. The smaller battery needs charging more often which is going to shorten it's lifespan. This might not be a problem if battery packs could be replaced easily and economically. Early adopters of the Leaf certainly got burned on replacement issues. I'd love to see a manufacturer touting how easily their packs could be serviced or replaced. "Should last the life of the car" isn't good enough for me.

For my own use a 60kwh would suffice in summer temperatures but I need more capacity to cope with cold temps. My EV is used for trade business not frequent long distance travel. So for me the sweet spot is between 75 and 85kwh. Moving to a VW id.4 from a 40kwy Leaf put me in that slot. I wouldn't want to go beyond that capacity because of the weight. My Leaf was well built and super reliable but I wouldn't upgrade to an Ariya because of Nissan's treatment of Leaf owners who did experience battery troubles.
 
The smaller battery needs charging more often which is going to shorten it's lifespan.
I don't think there's accurate evidence that this is the case for modern EVs, even if it were true with first-generation EVs. My 110 mile range (officially) MINI Cooper SE has 100,000+ miles on it with no detectable range degradation. And I've had to charge to 100% SoC virtually every day for the 4.5 years I've owned the EV.

It reminds me of how everyone was saying CDs would degrade within five years, and yet I have CDs purchased in 1985 that still work fine.
 
I don't think there's accurate evidence that this is the case for modern EVs, even if it were true with first-generation EVs. My 110 mile range (officially) MINI Cooper SE has 100,000+ miles on it with no detectable range degradation. And I've had to charge to 100% SoC virtually every day for the 4.5 years I've owned the EV.

It reminds me of how everyone was saying CDs would degrade within five years, and yet I have CDs purchased in 1985 that still work fine.
Thanks, @Puppethead, I was about to suggest small-battery (and compact-disc) deniers have a talk with you.
 
There is a trade off here. The smaller battery needs charging more often which is going to shorten it's lifespan. This might not be a problem if battery packs could be replaced easily and economically. Early adopters of the Leaf certainly got burned on replacement issues. I'd love to see a manufacturer touting how easily their packs could be serviced or replaced. "Should last the life of the car" isn't good enough for me.

For my own use a 60kwh would suffice in summer temperatures but I need more capacity to cope with cold temps. My EV is used for trade business not frequent long distance travel. So for me the sweet spot is between 75 and 85kwh. Moving to a VW id.4 from a 40kwy Leaf put me in that slot. I wouldn't want to go beyond that capacity because of the weight. My Leaf was well built and super reliable but I wouldn't upgrade to an Ariya because of Nissan's treatment of Leaf owners who did experience battery troubles.
AS mentioned above, battery life is not a thing here.Manufacturers selling replacement battery packs will happen as often as they now sell replacement engines. As in, almost never outside of warranty.
Junkyards will handle used battery packs, and eventually when market penetration is higher, and thus junkyards are full of damaged EVs, your mechanic will be able to find used battery packs of known condition locally
Replacing a battery pack is not unlike replacing large components in an ICE vehicle.

Look at the way the tech is going. My Niro has a 10-80 of something like 50 minutes. The newer EV6 that is 18 minutes.
That is real change.
I will venture to say that a one stop trip[say 350 miles] for either vehicle is not a big deal
But when you get to, say 3 stops, that is real. For a ~650 mile trip instead of 54 minutes, the Niro takes 2 1/2 hours of charging
That is a PITA. Makes it almost undoable in a day.

Now forget 5 minutes, say 9 minutes, half of a 3 year old Kia, you have 27 minutes of theoretical charging on a 650 mile trip.
That is killer
It is also down in the range where if you were using your car as an Uber and driving more than its range in a day, you would not be 'stuck charging'
 
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