Battery pre-heating prior to fast charge

1. A vehicle comprising:

a thermal system for a battery; and

a controller for the thermal system configured to,

during vehicle motion, cool the battery when a temperature of the battery exceeds a lower threshold and inhibit transfer of power with the battery when the temperature exceeds an upper threshold, and

while coupled with a charge station, heat the battery to a start temperature between the lower threshold and the upper threshold prior to flowing a current to the battery.

2. The vehicle of claim 1 , wherein the controller is further configured to, while coupled with a charge station, pre-heat the battery to a temperature less than the upper threshold by an amount the battery is predicted to rise.

3. The vehicle of claim 1 , wherein the controller is further configured to, during vehicle motion and a predicted arrival at a charge station at which a sum of a predicted change in temperature of the battery and a current battery temperature falls between the lower threshold and the upper threshold, inhibit cooling the battery.

4. The vehicle of claim 3 , wherein the controller is further configured to inhibit cooling the battery to permit the temperature of the battery to increase to a level less than the upper threshold by an amount the battery is predicted to rise while coupled with the charge station.

5. The vehicle of claim 3 , wherein the controller is further configured to inhibit cooling the battery to permit the temperature of the battery to increase to a level less than the upper threshold by an amount the battery is predicted to rise while coupled with the charge station, and activate a cooling system when the battery temperature is within a predetermined amount of the upper threshold.

6. The vehicle of claim 1 , wherein the battery includes a plurality of cells having a combined capacity of at least 50 Ah, and the controller is further configured to limit a flow of charge from a charge station to the battery to a rate greater than 1C.

7. The vehicle of claim 1 , wherein the battery includes a plurality of cells having a combined capacity of at least 20 Ah, and the controller is further configured to limit a flow of charge from a charge station to the battery to a rate greater than 1C.

8. The vehicle of claim 1 , wherein the controller is further configured to adjust a rate at which charge is provided to the battery as a function of a state of charge (SOC) of the battery such that the rate decreases as the SOC increases.

9. A method of controlling a vehicle traction battery comprising:

while in a key-on state, activating a battery cooler when a temperature of the battery is above a lower threshold, and restricting power transferred with the battery when the temperature is above an upper threshold; and

while coupled with a charge station, pre-heating the battery to a start temperature between the lower threshold and the upper threshold prior to flowing a current to the battery wherein the start temperature is based on an amount the battery is predicted to rise while coupled with the charge station.

10. The method of claim 9 , wherein the pre-heating includes disengaging a battery cooler when the battery is above the lower threshold.

11. The method of claim 9 , wherein the pre-heating the battery includes engaging a battery heater when the battery is above the lower threshold.

12. The method of claim 9 , wherein the vehicle traction battery has a terminal voltage of at least 60V DC and includes a plurality of cells each having a combined capacity of at least 50 Ah.

13. The method of claim 9 , wherein the vehicle traction battery has a terminal voltage of at least 60V DC and includes a plurality of cells each having a combined capacity of at least 20 Ah.

14. A battery system comprising:

a battery; and

a controller configured to

in response to a temperature of the battery exceeding an upper threshold during vehicle motion, inhibit transfer of power with the battery,

in response to the battery being coupled with a charge station, heat the battery to a start temperature between a lower threshold and the upper threshold, wherein the start temperature is based on an amount the battery is predicted to rise while coupled with the charge station, and

in response to the temperature exceeding the lower threshold during vehicle motion, cool the battery.

15. The battery system of claim 14 , wherein inhibiting transfer of power with the battery includes outputting a signal to open switches coupled between the battery and loads of the battery.

16. The battery system of claim 14 , wherein the controller is further configured to, during vehicle motion and a predicted arrival at a charge station at which a sum of a predicted change in temperature of the battery and a current battery temperature falls between the lower threshold and the upper threshold, inhibit cooling the battery to allow self-heating of the battery.

17. The battery system of claim 16 , wherein the controller is further configured to inhibit cooling the battery to permit the temperature of the battery to increase to a level less the upper threshold by an amount the battery is predicted to rise while coupled with the charge station.

18. The battery system of claim 16 , wherein the controller is further configured to inhibit cooling the battery to permit the temperature of the battery to increase to a level less than the upper threshold by an amount the battery is predicted to rise while coupled with the charge station and activate a cooling system when the battery temperature is within a predetermined amount of the upper threshold.

19. The battery system of claim 14 , wherein heating the battery includes activating a battery heater.