EV Battery Breakthrough Significantly Accelerates Charging Even in Low Temperatures

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      Winter challenges for electric vehicles may soon be resolved. A new manufacturing technique from the University of Michigan has resulted in faster charging times and longer ranges, even in extremely cold conditions.

      When winter arrives, many things slow down—temperatures, traffic, and even getting out of bed. Cold weather particularly hinders EVs, as batteries take longer to charge and must exert more effort to sustain performance, which in turn reduces range. This combination isn’t appealing for potential EV buyers, especially in regions with distinct seasons. However, engineers at the university may have found a solution to this battery issue: insulating the battery.

      “Charging an EV battery typically takes 30 to 40 minutes with fast charging, and this duration can exceed an hour during winter,” stated Neil Dasgupta, an associate professor at UM in mechanical engineering and materials science, and co-author of the research. “This is the challenge we aim to tackle.”

      A specialized coating on the battery’s exterior can prevent lithium plating, which negatively affects battery life, slows charging, and poses safety risks. This unwanted layer forms on the anode’s surface when lithium ions cannot move freely or quickly into the anode material. Such scenarios can occur during fast charging (when the battery is overloaded), in cold temperatures (where ion movement is slowed), or when the battery is fully charged (due to Li-ion saturation).

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      The engineering team at UM has developed a 20-nanometer-thick lithium borate-carbonate coating for the battery. By combining this glassy coating with a restructured high-efficiency electrode (created with a laser-patterned design), they have produced a Li-ion battery that charges rapidly and retains its capacity for a longer time.

      How long does it take to fully charge an EV now? About 500% faster than current speeds; in other words, under 10 minutes. This is comparable to a typical fuel stop or quick snack break. In terms of battery longevity, it would still retain around 97% capacity after 100 fast charges, and this can be achieved even at temperatures as low as 14°F (-10°C).

      According to the team, battery manufacturers wouldn’t need to overhaul their production methods significantly. “We see this approach as something that EV battery manufacturers could implement without major changes to their existing production facilities,” Dasgupta stated. “For the first time, we’ve demonstrated a way to enable extreme fast charging at low temperatures without compromising the energy density of lithium-ion batteries.”

      Since the Nissan Leaf made its debut in 2011 as the first mass-market EV from a major carmaker, EV charging times and ranges have significantly improved. Nonetheless, the modern EV landscape still grapples with concerns regarding range, charging durations, infrastructure, and battery replacement. We continue to maximize every bit of range available, whether by hypermiling, disabling climate control, or resorting to less-than-ideal commuting strategies. The UM team's advances suggest they are heading in the right direction, without the need to completely reinvent the EV.

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