Cell matching across multiple characteristics during battery assembly

Patent metadata

Field	Value
Publication number	US-2025334638-A1
Application number	US-202519177399-A
Country	US
Kind code	A1
Filing date	Apr 11, 2025
Priority date	Jan 6, 2017
Publication date	Oct 30, 2025
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

1 . (canceled)

2 . A method, comprising:
providing a plurality of cells associated with a plurality of cell characteristics; determining a set of compatible cells among the plurality of cells based at least in part on one or more of the plurality of cell characteristics associated with the plurality of cells; globally uniquifying the set of compatible cells to obtain a plurality of uniquified sets of compatible cells by removing duplicate cells that appear more than once within each set of compatible cells; selecting two or more cells among the plurality of uniquified sets of compatible cells; and assembling a battery by including the selected two or more cells.

3 . The method of claim 2 , further comprising:
identifying a batch compatibility number for the plurality of uniquified sets of compatible cells based at least in part on one or more of the plurality of cell characteristics associated with the plurality of uniquified sets of compatible cells, wherein the batch compatibility number indicates a number of compatible cells with that cell; and selecting the selected two or more cells according to the batch compatibility numbers.

4 . The method of claim 3 , wherein the battery includes a first cell with lowest or highest batch compatibility number among the compatible cells for each tied cell in the plurality of uniquified sets of compatible cells, wherein the tied cells have a same batch compatibility number.

5 . The method of claim 3 , wherein the tied cells are sorted based at least in part on a lowest batch compatibility number, wherein any empty uniquified sets of compatible cells are ordered last when breaking the tie.

6 . The method of claim 3 , wherein identifying the batch compatibility number includes generating a cell compatibility matrix which indicates, for the plurality of uniquified sets of compatible cells, whether a given pair of cells is compatible.

7 . The method of claim 2 , wherein cells included in the battery are compatible with each other and free of tied cells having a same batch compatibility number, wherein the batch compatibility number indicates a number of compatible cells with that cell.

8 . The method of claim 2 , wherein the plurality of cell characteristics includes one of more of: a capacity, an open circuit voltage, a resistance, or a self-discharge rate.

9 . The method of claim 2 , wherein the plurality of cells includes all cells from a same manufacturing run, the method further comprising:
assembling additional batteries using the plurality of uniquified sets of compatible cells, so as to minimize a number of leftover cells among the plurality of cells that are not included in any battery.

10 . A battery including a plurality of battery cells, the battery formed according to the method of claim 2 .

11 . The battery of claim 10 , wherein the plurality of battery cells match with each other on a subset or all of the plurality of cell characteristics.

12 . The battery of claim 10 , wherein two cells in the battery are compatible because a difference of their respective value for a given cell characteristic is below a predetermined threshold for the given cell characteristic.

13 . The battery of claim 10 , wherein two cells in the battery are compatible because a difference of their respective values for each one of the plurality of cell characteristics is below a predetermined threshold associated with each one of the plurality of cell characteristics.

14 . A computer program product, the computer program product being embodied in a non-transitory computer readable storage medium and comprising computer instructions for performing the method of claim 2 .

Assignees

• Wisk Aero Llc

Inventors

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

Classifications

• H01M10/4285

  Testing apparatus · CPC title

• H01M10/0404

  Machines for assembling batteries · 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

• G06F7/08

  Sorting, i.e. grouping record carriers in numerical or other ordered sequence according to the classification of at least some of the information they carry (by merging two or more sets of carriers in ordered sequence G06F7/16) · CPC title

• H01M10/482

  for several batteries or cells simultaneously or sequentially · CPC title