Cell matching across multiple characteristics during battery assembly

Patent metadata

Field	Value
Publication number	US-2019195954-A1
Application number	US-201916287882-A
Country	US
Kind code	A1
Filing date	Feb 27, 2019
Priority date	Jan 6, 2017
Publication date	Jun 27, 2019
Grant date	—

Abstract

For each cell in a plurality of cells from a same manufacturing run, a first and a second cell characteristic are received in order to obtain a plurality of cell characteristics. For each cell, a batch compatibility number that is associated with a number of compatible cells that that cell is compatible with is determined based at least in part on the plurality of cell characteristics. The plurality of cells is sorted according to the batch compatibility numbers to obtain a sorted list of cells. A plurality of compatible cells to include in a battery is selected from the plurality of cells, including by evaluating the plurality of cells according to the order of the sorted list of cells and beginning with the lowest batch compatibility number.

First claim

What is claimed is:

1 . A battery, comprising:
a container; a lid; and a plurality of compatible cells, wherein the plurality of compatible cells included in the battery is selected from a plurality of cells, including by:
for each cell in the plurality of cells, receiving a first cell characteristic and a second cell characteristic in order to obtain a plurality of cell characteristics, wherein the plurality of cells are from a same manufacturing run;
for each cell in the plurality of cells, determining, based at least in part on the plurality of cell characteristics, a batch compatibility number that is associated with a number of compatible cells that that cell is compatible with;
sorting the plurality of cells according to the batch compatibility numbers in order to obtain a sorted list of cells; and
selecting the plurality of compatible cells to include in the battery from the plurality of cells, including by evaluating the plurality of cells according to the order specified by the sorted list of cells and beginning with a cell with the lowest batch compatibility number.

2 . The battery recited in claim 1 , wherein the first cell characteristic includes one of the following: capacity, open circuit voltage, resistance, or self-discharge rate.

3 . The battery recited in claim 1 , wherein determining the batch compatibility number includes generating a cell compatibility matrix which indicates, for the plurality of cells, whether a given pair of cells is compatible.

4 . The battery recited in claim 1 , wherein determining the batch compatibility number includes:
determining a first difference between a first cell in the plurality of cells and a second cell in the plurality of cells for the first cell characteristic; determining a second difference between the first cell and the second cell for the second cell characteristic; and in the event (1) the first difference does not exceed a first tolerance associated with the first cell characteristic and (2) the second difference does not exceed a second tolerance associated with the second cell characteristic, declaring the first cell and the second cell to be compatible.

5 . The battery recited in claim 1 , wherein sorting the plurality of cells includes:
determining, for each tied cell in a plurality of tied cells, a set of compatible cells in order to obtain a plurality of sets of compatible cells; and breaking a tie between the plurality of tied cells based at least in part on uniqueness associated with the plurality of sets of compatible cells and one or more batch compatibility numbers associated with the plurality of sets of compatible cells.

6 . The battery recited in claim 1 , wherein:
sorting the plurality of cells includes:
determining, for each tied cell in a plurality of tied cells, a set of compatible cells in order to obtain a plurality of sets of compatible cells; and
breaking a tie between the plurality of tied cells based at least in part on uniqueness associated with the plurality of sets of compatible cells and one or more batch compatibility numbers associated with the plurality of sets of compatible cells; and
breaking the tie between the plurality of tied cells includes:
sorting the plurality of sets of compatible cells based at least in part on the batch compatibility numbers associated with the plurality of sets of compatible cells to obtain a plurality of sorted lists of compatible cells;
selecting two or more compatible cells to compare from different sorted lists of compatible cells, wherein the selected compatible cells are at a same level in their respective sorted lists of compatible cells; and
in the event a minimum batch compatibility number, associated with the selected compatible cells to compare, is unique, selecting a tied cell, associated with the minimum and unique batch compatibility number, as a tiebreak winner.

7 . A method, comprising:
for each cell in a plurality of cells, receiving a first cell characteristic and a second cell characteristic in order to obtain a plurality of cell characteristics, wherein the plurality of cells are from a same manufacturing run; for each cell in the plurality of cells, determining, based at least in part on the plurality of cell characteristics, a batch compatibility number that is associated with a number of compatible cells that that cell is compatible with; sorting the plurality of cells according to the batch compatibility numbers in order to obtain a sorted list of cells; and selecting a plurality of compatible cells to include in a battery from the plurality of cells, including by evaluating the plurality of cells according to the order specified by the sorted list of cells and beginning with a cell with the lowest batch compatibility number, wherein the plurality of compatible cells are included in the battery.

8 . The method recited in claim 7 , wherein the first cell characteristic includes one of the following: capacity, open circuit voltage, resistance, or self-discharge rate.

9 . The method recited in claim 7 , wherein determining the batch compatibility number includes generating a cell compatibility matrix which indicates, for the plurality of cells, whether a given pair of cells is compatible.

10 . The method recited in claim 7 , wherein determining the batch compatibility number includes:
determining a first difference between a first cell in the plurality of cells and a second cell in the plurality of cells for the first cell characteristic; determining a second difference between the first cell and the second cell for the second cell characteristic; and in the event (1) the first difference does not exceed a first tolerance associated with the first cell characteristic and (2) the second difference does not exceed a second tolerance associated with the second cell characteristic, declaring the first cell and the second cell to be compatible.

11 . The method recited in claim 7 , wherein sorting the plurality of cells includes:
determining, for each tied cell in a plurality of tied cells, a set of compatible cells in order to obtain a plurality of sets of compatible cells; and breaking a tie between the plurality of tied cells based at least in part on uniqueness associated with the plurality of sets of compatible cells and one or more batch compatibility numbers associated with the plurality of sets of compatible cells.

12 . The method recited in claim 7 , wherein:
sorting the plurality of cells includes:
determining, for each tied cell in a plurality of tied cells, a set of compatible cells in order to obtain a plurality of sets of compatible cells; and
breaking a tie between the plurality of tied cells based at least in part on uniqueness associated with the plurality of sets of compatible cells and one or more batch compatibility numbers associated with the plurality of sets of compatible cells; and
breaking the tie between the plurality of tied cells includes:
sorting the plurality of sets of compatible cells based at least in part on the batch compatibility numbers associated with the plurality of sets of compatible cells to obtain a plurality of sorted lists of compatible cells;
selecting two or more compatible cells to compare from different sorted lists of compatible cells, wherein the selected compatible cells are at a same level in their respective sorted lists of compatible cells; and
in the event a minimum batch compatibility number, associated with the selected compatible cells to compare, is unique, selecting a tied cell, associated with the minimum and unique batch compatibility number, as a tiebreak winner.

13 . A computer pro

Assignees

• Kitty Hawk Corp

Inventors

• Hom Lewis Romeo
• Muniz Thomas P
• Herring Patrick K

Classifications

• H01M10/482

  for several batteries or cells simultaneously or sequentially · CPC title

• H01M6/5011 Primary

  for several cells simultaneously or successively · CPC title

• G01R31/396

  Acquisition or processing of data for testing or for monitoring individual cells or groups of cells within a battery · CPC title

• G01R31/367 Primary

  Software therefor, e.g. for battery testing using modelling or look-up tables · CPC title

• H01M10/0404

  Machines for assembling batteries · CPC title