Method for sorting used secondary battery, rebuilt battery pack, vehicle and battery operated device incorporating same, and method for manufacturing rebuilt battery pack

• US 9,515,355 B2
• Filed: 03/31/2010
• Issued: 12/06/2016
• Est. Priority Date: 03/31/2010
• Status: Active Grant

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Ito, Masanori
• Primary Examiner(s): Barnie, Rexford
• Assistant Examiner(s): Ly, Xuan
• Application Number:
  US13/637,763
• Publication Number:
  US 20130015702A1
• Time in Patent Office: 2,442 Days
• Field of Search: 307/9.1, 320/128, 320/132, 320/106, 429/430, 429/434, 414/274
• US Class Current: 1/1
• CPC Class Codes: H01M 10/0525 Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
• CPC Class Codes: H01M 10/30 Nickel accumulators H01M10/34 takes precedence
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 10/54 Reclaiming serviceable parts of waste accumulators
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02W 30/84 Recycling of batteries or fuel cells

Abstract

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.

Claims

1. A method for sorting a used secondary battery having been already used, the battery having characteristics such that

in an initial stage of a usable period, a battery resistance is gradually reduced and an initial-stage high-resistance period having a relatively high battery resistance appears,

in a middle stage of the usable period, a middle-stage low-resistance period having a relatively loan battery resistance appears, and

in an ending stage of the usable period, the battery resistance is gradually raised and an ending-stage high-resistance period having a relatively high battery resistance appears,

wherein the method includes:

a resistance measuring step of measuring the battery resistance of the used secondary battery; and

a resistance distinguishing step of distinguishing whether the battery resistance of the used secondary battery is high or low as compared with a period threshold identifying whether the used secondary battery is present in one of the initial-stage high-resistance period or ending-stage high-resistance period and the middle-stage low-resistance period.

2. The method for sorting a used secondary battery according to claim 1, further including a period distinguishing step of distinguishing whether the used secondary battery having the higher battery resistance than the period threshold belongs to the initial-stage high-resistance period or the ending-stage high-resistance period based on used history information of the used secondary battery.

3. The method for sorting a used secondary battery according to claim 1, further including a resistance classifying step of further classifying the used secondary battery having the lower battery resistance than the period threshold into a plurality of layers based on a magnitude of the battery resistance.

4. The method for sorting a used secondary battery according to claim 1, wherein

the used secondary battery has characteristics such that

in a usable temperature range of the battery,

a DC resistance of the battery is increased as a temperature of the battery is lowered, and

a change in the DC resistance due to the temperature is small in a high temperature region having a relatively high temperature, and

a change in the DC resistance due to the temperature is large in a low temperature region having a relatively low temperature, and the DC resistance in the low temperature region is equal to or more than three times as high as the DC resistance in the high temperature region, and

the DC resistance is acceleratively increased as the temperature of the battery is lowered in a middle temperature region between the high temperature region and the low temperature region, and

the method includes a discharging-time classifying step of further classifying, in an environment of the middle temperature region, the used secondary battery having the smaller battery resistance than the period threshold, into a plurality of layers based on a length of a discharging time of constant power discharging or constant current discharging which is started at a predetermined discharging start voltage within a highest voltage range defined as an uppermost ⅕

of an allowable voltage range ranging from a minimum allowable voltage to a maximum allowable voltage, and ended at a predetermined discharging end voltage within a lowest voltage range defined as a lowermost ⅕

of the allowable voltage range.

5. A rebuilt battery pack reconstituted by collecting a plurality of used secondary batteries having been already used, the batteries having characteristics such that

in an initial stage of a usable period, a battery resistance is gradually reduced and an initial-stage high-resistance period having a relatively high battery resistance appears,

in a middle stage of the usable period, a middle-stage low-resistance period having a relatively low battery resistance appears, and

in an ending stage of the usable period, the battery resistance is gradually raised and an ending-stage high-resistance period having a relatively high battery resistance appears,

wherein each of the used secondary batteries is distinguished to be in the middle-stage low-resistance period by the method for sorting a used secondary battery according to claim 1.

6. A rebuilt battery pack reconstituted by collecting a plurality of used secondary batteries having been already used, the batteries having characteristics such that

in an initial stage of a usable period, a battery resistance is gradually reduced and an initial-stage high-resistance period having a relatively high battery resistance appears,

in a middle stage of the usable period, a middle-stage low-resistance period having a relatively low battery resistance appears, and

in an ending stage of the usable period, the battery resistance is gradually raised and an ending-stage high-resistance period having a relatively high battery resistance appears,

wherein each of the used secondary batteries is distinguished to be in the initial-stage high-resistance period by the method for sorting a used secondary battery according to claim 2.

7. A rebuilt battery pack reconstituted by collecting a plurality of used secondary batteries having been already used, the batteries having characteristics such that

in an initial stage of a usable period, a battery resistance is gradually reduced and an initial-stage high-resistance period having a relatively high battery resistance appears,

in a middle stage of the usable period, a middle-stage low-resistance period having a relatively low battery resistance appears, and

in an ending stage of the usable period, the battery resistance is gradually raised and an ending-stage high-resistance period having a relatively high battery resistance appears,

wherein the used secondary batteries belong to one layer or some adjacent layers of the plurality of layers classified in the resistance classifying step according to claim 3.

8. A rebuilt battery pack reconstituted by collecting a plurality of used secondary batteries having been already used, the batteries having characteristics such that

in an initial stage of a usable period, a battery resistance is gradually reduced and an initial-stage high-resistance period having a relatively high battery resistance appears,

in a middle stage of the usable period, a middle-stage low-resistance period having a relatively low battery resistance appears, and

in an ending stage of the usable period, the battery resistance is gradually raised and an ending-stage high-resistance period having a relatively high battery resistance appears,

wherein the used secondary batteries belong to one layer or some adjacent layers of the plurality of layers classified in the discharging-time classifying step according to claim 4.

10. A vehicle on which the rebuilt battery pack according to claim 5 is mounted, the vehicle using electric energy of the rebuilt battery pack for a whole or partial power source.

11. A battery operated device on which the rebuilt battery pack according to claim 5 is mounted, the battery operated device using the rebuilt battery pack as at least one of energy sources.

15. A vehicle on which the rebuilt battery pack according to claim 6 is mounted, the vehicle using electric energy of the rebuilt battery pack for a whole or partial power source.

16. A vehicle on which the rebuilt battery pack according to claim 7 is mounted, the vehicle using electric energy of the rebuilt battery pack for a whole or partial power source.

17. A vehicle on which the rebuilt battery pack according to claim 8 is mounted, the vehicle using electric energy of the rebuilt battery pack for a whole or partial power source.

9. A rebuilt battery pack reconstituted by collecting a plurality of used secondary batteries having been already used, the batteries having characteristics such that

in an initial stage of a usable period, a battery resistance is gradually reduced and an initial-stage high-resistance period having a relatively high battery resistance appears,

in a middle stage of the usable period, a middle-stage low-resistance period having a relatively low battery resistance appears, and

in an ending stage of the usable period, the battery resistance is gradually raised and an ending-stage high-resistance period having a relatively high battery resistance appears,

wherein each of the used secondary batteries belongs to the middle-stage low-resistance period.

18. A vehicle on which the rebuilt battery pack according to claim 9 is mounted, the vehicle using electric energy of the rebuilt battery pack for a whole or partial power source.

12. A method of manufacturing a rebuilt battery pack reconstituted by collecting a plurality of used secondary batteries having been already used, the batteries having characteristics such that

in an initial stage of a usable period, a battery resistance is gradually reduced and an initial-stage high-resistance period having a relatively high battery resistance appears,

in a middle stage of the usable period, a middle-stage low-resistance period having a relatively low battery resistance appears, and

in an ending stage of the usable period, the battery resistance is gradually raised and an ending-stage high-resistance period having a relatively high battery resistance appears,

wherein the method includes:

a resistance distinguishing step of distinguishing whether the battery resistance of the used secondary battery is high or low as compared with a period threshold identifying whether the used secondary battery is present in one of the initial-stage high-resistance period or ending-stage high-resistance period and the middle-stage low-resistance period; and

a first type reconstituting step of collecting the used secondary batteries having the lower battery resistance than the period threshold to reconstitute the battery pack.

13. The method of manufacturing a rebuilt battery pack according to claim 12, further including:

a resistance classifying step of classifying the used secondary batteries having a lower battery resistance than the period threshold into a plurality of layers based on a magnitude of the battery resistance; and

a second type reconstituting step, in place of the first type reconstituting step, of collecting the used secondary batteries belonging to one layer or some adjacent layers of the plurality of layers classified by the battery resistance to reconstitute a battery pack.

14. The method of manufacturing the rebuilt battery pack according to claim 12, wherein

the used secondary battery has characteristics such that

in a usable temperature range of the battery,

a DC resistance of the battery is increased as a temperature of the battery is lowered, and

a change in the DC resistance due to the temperature is small in a high temperature region having a relatively high temperature, and

a change in the DC resistance due to the temperature is large in a low temperature region having a relatively high temperature, and the DC resistance in the low temperature region is equal to or more than three times as high as the DC resistance in the high temperature region, and

the DC resistance is acceleratively increased as the temperature of the battery is lowered in a middle temperature region between the high temperature region and the low temperature region,

the method includes:

a discharging-time classifying step of further classifying, in an environment of the middle temperature region, the used secondary batteries having the smaller battery resistance than the period threshold or classified in the resistance classifying step, into a plurality of layers based on a length of a discharging time of constant power discharging or constant current discharging which is started at a predetermined discharging start voltage within a highest voltage range defined as an uppermost ⅕

of an allowable voltage range ranging from a minimum allowable voltage to a maximum allowable voltage, and ended at a predetermined discharging end voltage within a lowest voltage range defined as a lowermost ⅕

of the allowable voltage range; and

a third type reconstituting step, provided in place of the first type reconstituting step, of reconstituting the battery pack by collecting the used secondary batteries belonging to one layer or some adjacent layers of the plurality of layers classified based on the length of the discharging time.