Used Battery Sorting by Resistance Thresholds

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Used secondary batteries with varying characteristics and degrees of deterioration pose challenges in forming stable and usable battery packs, leading to potential overvoltage, overcharge, early battery rundown, and reduced lifespan when rebuilt, due to differences in resistance and usage history.

Innovation Solution

A method for sorting used secondary batteries based on resistance measurements and history, categorizing them into initial-stage high-resistance, middle-stage low-resistance, and ending-stage high-resistance periods, and further classifying them by resistance magnitude and discharging time to ensure uniformity and stability in rebuilt battery packs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If used secondary batteries with varying characteristics are collected to rebuild battery packs, then the quantity of usable batteries increases and resource utilization improves, but the reliability and stability of the rebuilt battery packs deteriorate due to variations in resistance and degree of deterioration

Engineering Contradiction:
Improvequantity of usable batteriesVSAvoidstability of rebuilt battery pack
Core Design Contradiction:
Quantity of substanceVSReliability

Solution Approach 1:

The patent segments used secondary batteries into three distinct groups based on their resistance characteristics: initial-stage high-resistance batteries, middle-stage low-resistance batteries, and ending-stage high-resistance batteries. This segmentation allows batteries with similar characteristics to be grouped together, ensuring uniform performance within each group while maximizing the utilization of all usable batteries across the three stages.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent uses battery resistance as a key parameter to classify and sort used secondary batteries. By measuring and comparing resistance values against predefined thresholds, the system identifies which stage each battery is in and assigns it to the appropriate group. This parameter-based classification ensures that batteries are rebuilt in packs with uniform characteristics, maintaining reliability while increasing the quantity of usable batteries.

Inventive Principle:
Principle #35Parameter changes

2Quantity of substance

If batteries from different usage stages are mixed in rebuilt battery packs, then more used batteries can be utilized, but harmful effects such as overvoltage, overcharge, and early battery rundown occur

Engineering Contradiction:
Improveutilization of used batteriesVSAvoidovervoltage, overcharge, early rundown
Core Design Contradiction:
Quantity of substanceVSObject-generated harmful factors

Solution Approach 1:

The patent divides used batteries into three separate segments based on their resistance characteristics corresponding to different usage stages. By keeping batteries from different stages separated into distinct groups, the system prevents mixing batteries with vastly different characteristics, thereby avoiding harmful effects like overvoltage, overcharge, and early rundown that would occur if heterogeneous batteries were combined in the same pack.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies local quality by assigning batteries to specific groups based on their individual resistance characteristics and usage stage. Each group (initial-stage, middle-stage, ending-stage) has uniform local qualities in terms of resistance and deterioration level, ensuring that batteries within each group behave consistently during charging and discharging, thus preventing harmful effects.

Inventive Principle:
Principle #3Local quality

3Stability of the object's composition

If resistance measurement and classification methods are implemented for sorting used batteries, then the uniformity and stability of rebuilt battery packs improve, but the complexity of the sorting process increases

Engineering Contradiction:
Improveuniformity of battery characteristicsVSAvoidcomplexity of sorting process
Core Design Contradiction:
Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent implements a sorting system that measures battery resistance and compares it against predefined threshold values to classify batteries into three stages. This parameter-based approach provides a simple yet effective method for achieving uniformity in rebuilt battery packs. The use of clear resistance thresholds and straightforward classification rules minimizes sorting process complexity while ensuring stable and uniform battery characteristics in the final packs.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS9515355B2Method for sorting used secondary battery, rebuilt battery pack, vehicle and battery operated device incorporating same, and method for manufacturing rebuilt battery pack
Publication Date: 2016.12.06 TOYOTA JIDOSHA KK
  • US9515355B2 patent drawing
  • US9515355B2 patent drawing
  • US9515355B2 patent drawing

AI summary

Disclosed are a method for adequately sorting used secondary batteries; a rebuilt battery pack that incorporates the used batteries sorted by the sorting method and have identical characteristics; a vehicle and a battery operated device which use the rebuilt battery pack; and a method for manufacturing a rebuilt battery pack which employs used batteries having identical characteristics. The method for sorting used secondary batteries includes a resistance measurement step for measuring the battery resistance of a battery the characteristics of which show a bathtub curve with respect to the period of use. The method further includes a resistance distinguishing step for distinguishing whether the battery resistance of the battery is greater or less than a period threshold value for identifying to which one of the following periods the battery belongs: an initial-stage high-resistance period, and end-stage high-resistance period, and a middle-stage low-resistance period.