  The long charge time of electric vehicles compared with the refueling time of
gasoline 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 as
Tesla with fast charging capabilities is >30 minutes. For a comparable
recharging experience as gasoline vehicles, governments and automobile
companies have set <15 min with 500 cycles as the goal for extreme fast
charging (XFC) of electric vehicles. One of the biggest challenges to enable
XFC for lithium-ion batteries (LIBs) is to avoid lithium plating. Although
significant research is taking place to enable XFC, no promising
technology/strategy has still emerged for mainstream commercial LIBs. Here, we
propose a thermally modulated charging protocol (TMCP) by active thermal
switching for XFC, i.e., retaining the battery heat during XFC with the switch
OFF for boosting the kinetics to avoid lithium plating while dissipating the
heat after XFC with the switch ON for reducing side reactions. Our proposed
TMCP strategy enables XFC of commercial high-energy-density LIBs with charge
time <15 min and >500 cycles while simultaneously beating other targets set by
US 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 and
demonstrate the feasibility of integrating our TMCP in commercial battery
thermal management system.
