EV Battery Repurposing With Threshold-Based Second-Life Matching

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Electric vehicle batteries lose efficiency over time, necessitating replacement before they can effectively power the vehicle, while still retaining capacity that could be utilized in other devices.

Innovation Solution

A method and system to determine when a battery loses efficiency below a threshold, identify suitable devices for repurposing the battery, and provide a net gain or loss analysis for replacing the battery in the vehicle versus using it in another location.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the battery is kept in the electric transport, then the transport can operate, but the battery efficiency deteriorates below threshold over time

Engineering Contradiction:
Improvebattery efficiencyVSAvoidbattery replacement timing
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary assessment of battery efficiency and predicts future performance degradation. By evaluating battery health metrics and operational patterns in advance, the system determines the optimal replacement timing before efficiency drops below the threshold, allowing proactive scheduling of battery replacement and repurposing actions.

Inventive Principle:
Principle #10Preliminary action

2Reliability

If the battery is replaced in the electric transport, then the transport efficiency is maintained, but the removed battery is wasted

Engineering Contradiction:
Improvetransport efficiencyVSAvoidbattery capacity
Core Design Contradiction:
ReliabilityVSLoss of substance

Solution Approach 1:

Instead of discarding the removed battery, the system recovers its remaining capacity by identifying suitable external devices that can utilize the battery's residual energy. The system assesses the battery's remaining capacity and matches it with devices having compatible power requirements, thereby recovering value from what would otherwise be waste.

Inventive Principle:
Principle #34Discarding and recovering

Solution Approach 2:

The battery is designed to serve multiple functions across different applications. Initially, it powers the electric transport, and after replacement, it is repurposed to power external devices such as home appliances, emergency power systems, or smaller electric vehicles, maximizing its utility throughout its service life.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Duration of action of moving object

If the battery is repurposed to power external devices, then battery life is extended, but the transport may experience power availability issues

Engineering Contradiction:
Improvebattery service lifeVSAvoidtransport power availability
Core Design Contradiction:
Duration of action of moving objectVSReliability

Solution Approach 1:

The system performs preliminary evaluation of both the transport's power needs and the external device's power requirements before repurposing the battery. It calculates whether the battery's remaining capacity is sufficient for the external device while ensuring the transport has adequate power availability, preventing future power shortages in the transport.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS12427887B2Transport battery repurposing
Publication Date: 2025.09.30 TOYOTA MOTOR ENG & MFG NORTH AMERICA INC
  • US12427887B2 patent drawing
  • US12427887B2 patent drawing
  • US12427887B2 patent drawing

AI summary

An example operation includes one or more of determining a time when a battery of an electric transport loses efficiency below a threshold, determining a device apart from the transport that can be powered above the threshold using the battery, and providing a net gain or a net loss related to the electric transport and the device, when the battery is removed from the electric transport to power the device.