Reusable Bipolar Battery Assembly Through Closed-Loop Component Recovery

The patent applies discarding and recovering by collecting spent battery plates, current collectors, and other components after the battery reaches end-of-life, then reprocessing and reusing these materials to manufacture new battery assemblies. This eliminates the need to extract virgin materials and reduces the energy and resources required for producing replacement batteries, effectively extending the lifecycle of battery materials without requiring thicker or heavier components in the first place.

The patent applies parameter changes by modifying the processing parameters and methods used in battery component recovery. Instead of traditional high-energy-intensive recycling processes, the patent employs optimized mechanical processing, selective disassembly techniques, and controlled reprocessing parameters that significantly reduce energy consumption while maintaining high material recovery rates. This includes using lower-temperature processing methods and more efficient separation techniques.

The patent applies segmentation by dividing the battery recycling process into distinct modular stages: initial deactivation, mechanical disassembly, component separation, and reprocessing. Each stage is independently optimized and can be performed by specialized equipment or processes. This modular approach simplifies the overall complex recycling process, makes it more manageable and efficient, and allows for parallel processing of different battery types and chemistries.

The patent applies discarding and recovering by establishing a closed-loop system where battery assemblies that have reached end-of-life due to deep cycling-induced degradation are systematically collected, disassembled, and reprocessed. The spent active materials, current collectors, and structural components are recovered and reused in new battery assemblies. This approach effectively decouples the relationship between deep cycling intensity and overall system reliability, as the degraded components are continuously replenished from recovered materials rather than requiring prevention of degradation through reduced cycling intensity.