Cell Architecture Design for Fast-Charging Lithium-Ion Batteries in Electric Vehicles

Abstract

This paper reviews the growing demand for and importance of fast and ultra-fast charging in lithium-ion batteries (LIBs) for electric vehicles (EVs). Fast charging is critical to improving EV performance and is crucial in reducing range concerns to make EVs more attractive to consumers. We focused on the design aspects of fast- and ultra-fast-charging LIBs at different levels, from internal cell architecture, through cell design, to complete system integration within the vehicle chassis. This paper explores battery internal cell architecture, including how the design of electrodes, electrolytes, and other factors may impact battery performance. Then, we provide a detailed review of different cell format characteristics in cylindrical, prismatic, pouch, and blade shapes. Recent trends, technological advancements in tab design and placement, and shape factors are discussed with a focus on reducing ion transport resistance and enhancing energy density. In addition to cell-level modifications, pack and chassis design must be implemented across aspects such as safety, mechanical integrity, and thermal management. Considering the requirements and challenges of high-power charging systems, we examined how modules, packs, and the vehicle chassis should be adapted to provide fast and ultra-fast charging. In this way, we explored the potential of fast and ultra-fast charging by investigating the required modification of individual cells up to their integration into the EV system through pack and chassis design.