IP Library Granted Patent US 12680422
Granted Patent B2
US 12680422 · App. 18/405,989 · Granted Jul 14, 2026

Method for powering with a hybrid battery pack system

Inventors: Wu Bi (Katy, TX); Xu Wang (Beijing, CN); Peng Cheng (Sugar Land, TX); Jiaxiang Ren (Houston, TX)
Assignee: CNPC USA Corporation
E21B41/0085E21B47/07H01M4/587H01M10/052H01M10/0567H01M10/0569H01M10/4207H01M10/425H01M10/486H01M50/204H01M50/296H02J7/80H02J7/855H02J7/977H01M2010/4271H01M2200/108H01M2220/10H01M2300/0037
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Quick Facts
Patent No.
US 12680422
App. No.
18/405,989
Granted
Jul 14, 2026
Kind
B2
Abstract

The hybrid battery system includes a primary battery pack, a secondary battery pack, a battery control unit, a battery pack positive terminal, and a battery pack negative terminal. The battery control unit includes a management module and a variable resistor. The primary battery pack supplies power at lower temperatures, while the secondary battery pack supplies power at higher temperatures. The primary battery pack is unsafe at higher temperatures, and the primary cells within the primary battery pack are modified to mitigate the dangers that previously rendered the primary battery pack unusable in a hybrid battery pack at higher temperatures. The invention includes the method of safely operating the hybrid battery system with the modified primary battery cells of the primary battery pack.

Claims (115)

1 . A method for powering, comprising the steps of:

connecting an external electric application device of a downhole tool to a hybrid battery system, at said battery pack positive terminal and at said battery pack negative terminal,

wherein the hybrid battery system comprises:

a primary battery pack being comprised of a primary negative terminal and a primary positive terminal, the primary battery pack comprising:

a primary first battery cell being comprised of a primary first negative terminal connected to the primary negative terminal and a primary first positive terminal connected to the primary positive terminal;

a primary first negative electrode being comprised of a primary first electrode metal and being connected to the primary first negative terminal;

a primary first carbon electrode being comprised of primary first carbon materials and being connected to the primary first positive terminal, the primary first carbon electrode having porous structures;

a primary first separator between the primary first negative electrode and the primary first carbon electrode; and

a primary first cathodic solution being within said primary first battery cell and in contact with said primary first negative electrode, said primary first separator, and said primary first carbon electrode,

wherein the primary first cathodic solution comprises a primary first solvent system and a primary first electrolyte salt;

a secondary battery pack being comprised of a secondary negative terminal and a secondary positive terminal, the secondary battery pack comprising:

a secondary first battery cell being comprised of a secondary first negative terminal connected to the secondary negative terminal and a secondary first positive terminal connected to the secondary positive terminal;

a secondary first negative electrode being comprised of a secondary first electrode metal and being connected to the secondary first negative terminal;

a secondary first carbon electrode being comprised of secondary first carbon materials and being connected to the secondary first positive terminal, the secondary first carbon electrode having porous structures;

a secondary first separator between the secondary first negative electrode and the secondary first carbon electrode; and

a secondary first cathodic solution being within said secondary first battery cell and in contact with said secondary first negative electrode, said secondary first separator, and said secondary first carbon electrode,

wherein the secondary first cathodic solution comprises a secondary first solvent system and a secondary first electrolyte salt,

wherein the primary first electrode metal has a primary first melting point,

wherein the primary first battery cell has a primary first rated temperature range;

wherein the secondary first electrode metal has a secondary first melting point,

wherein the secondary first battery cell has a secondary first rated temperature range;

wherein the secondary first rated temperature range is higher than the primary first rated temperature range,

wherein the primary first electrode metal has a primary first electrode metal charge capacity,

wherein the primary first cathodic solution has a primary first positive charge capacity,

wherein the primary first electrode metal charge capacity is lower than the primary first positive charge capacity,

wherein the primary first battery cell is comprised of a primary first battery housing with a primary first battery headspace,

wherein the secondary first battery cell is comprised of a secondary first battery housing with a secondary first battery headspace, and

wherein a primary first battery headspace percentage of said primary first battery housing is greater than a secondary first battery headspace percentage of said secondary first battery housing;

a battery control unit being in communication with the primary battery pack and the secondary battery pack, the battery control unit being comprised of a management module and a variable resistor;

a battery pack positive terminal connected to the battery control unit; and

a battery pack negative terminal connected to the battery control unit;

measuring a monitored temperature of the hybrid battery system;

generating a primary first voltage discharge level by reactions with the primary first electrode metal and the primary first cathodic solution, when the monitored temperature is within the primary first rated temperature range;

deploying the downhole tool into a borehole;

generating a secondary first voltage discharge level by reactions with the secondary first electrode metal and the secondary first cathodic solution, when the monitored temperature is within the secondary first rated temperature range;

increasing resistance of the variable resistor to the primary battery pack with the management module before the monitored temperature is greater than the primary first rated temperature range; and

stripping the primary first electrode metal from the primary first battery cell before the monitored temperature exceeds the primary first rated temperature range.

2 . The method for powering, according to claim 1 , further comprising the step of:

disconnecting the external device from said primary battery pack before the step of increasing resistance; and

connecting said variable resistor to said primary battery pack before the step of increasing resistance.

3 . The method for powering, according to claim 1 ,

wherein the primary first cathodic solution is further comprised of a co-solvent with a boiling point higher a boiling point of said primary first solvent system.

4 . The method for powering, according to claim 3 , further comprising the step of:

dissolving the primary first electrolyte salt in the primary first cathodic solution so at to minimize internal vapor pressure of the primary first battery cell.

5 . The method for powering, according to claim 1 , further comprising the step of:

reducing any residual primary first electrode metal within the primary first cathodic solution so as to accumulate internal electrolyte vapor in said primary first battery headspace.

6 . The method for powering, according to claim 1 , wherein the primary first voltage discharge level is greater than 2.0V in the step of generating the primary first voltage discharge level.

7 . The method for powering, according to claim 6 , further comprising the steps of:

decreasing the primary first voltage discharge level from greater than 2.0V;

increasing resistance of the variable resistor with the management module when the primary first voltage discharge level is less than 2.0V; and

stripping the primary first electrode metal from the primary first battery cell when the primary first voltage discharge level is less than 2.0V.

8 . A method for powering, comprising the steps of:

connecting an external electric application device of a downhole tool to a hybrid battery system, at the battery pack negative terminal and at the battery pack positive terminal,

wherein the hybrid battery system comprises:

a primary battery pack being comprised of a primary negative terminal and a primary positive terminal, the primary battery pack comprising:

a primary first battery cell being comprised of a primary first negative terminal connected to the primary negative terminal and a primary first positive terminal connected to the primary positive terminal;

a primary first negative electrode being comprised of a primary first electrode metal and being connected to the primary first negative terminal;

a primary first carbon electrode being comprised of primary first carbon materials and being connected to the primary first positive terminal, the primary first carbon electrode having porous structures;

a primary first separator between the primary first negative electrode and the primary first carbon electrode; and

a primary first cathodic solution being within said primary first battery cell and in contact with said primary first negative electrode, said primary first separator, and said primary first carbon electrode,

wherein the primary first cathodic solution comprises a primary first solvent system and a primary first electrolyte salt;

a secondary battery pack being comprised of a secondary negative terminal and a secondary positive terminal, the secondary battery pack comprising:

a secondary first battery cell being comprised of a secondary first negative terminal connected to the secondary negative terminal and a secondary first positive terminal connected to the secondary positive terminal;

a secondary first negative electrode being comprised of a secondary first electrode metal and being connected to the secondary first negative terminal;

a secondary first carbon electrode being comprised of secondary first carbon materials and being connected to the secondary first positive terminal, the secondary first carbon electrode having porous structures;

a secondary first separator between the secondary first negative electrode and the secondary first carbon electrode; and

a secondary first cathodic solution being within said secondary first battery cell and in contact with said secondary first negative electrode, said secondary first separator, and said secondary first carbon electrode,

wherein the secondary first cathodic solution comprises a secondary first solvent system and a secondary first electrolyte salt,

wherein the primary first electrode metal has a primary first melting point,

wherein the primary first battery cell has a primary first rated temperature range;

wherein the secondary first electrode metal has a secondary first melting point,

wherein the secondary first battery cell has a secondary first rated temperature range;

wherein the secondary first rated temperature range is higher than the primary first rated temperature range,

wherein the primary first electrode metal has a primary first electrode metal charge capacity

wherein the primary first cathodic solution has a primary first positive charge capacity,

wherein the primary first electrode metal charge capacity is lower than the primary first positive charge capacity,

wherein the primary first battery cell is comprised of a primary first battery housing with a primary first battery headspace,

wherein the secondary first battery cell is comprised of a secondary first battery housing with a secondary first battery headspace, and

wherein a primary first battery headspace percentage of said primary first battery housing is greater than a secondary first battery headspace percentage of said secondary first battery housing;

a battery control unit being in communication with the primary battery pack and the secondary battery pack, the battery control unit being comprised of a management module and a variable resistor;

a battery pack positive terminal connected to the battery control unit; and

a battery pack negative terminal connected to the battery control unit,

wherein the primary battery pack further comprises:

a primary second battery cell being comprised of a primary second negative terminal connected to the primary negative terminal and a primary second positive terminal connected to the primary positive terminal;

a primary second negative electrode being comprised of a primary second electrode metal and being connected to the primary second negative terminal;

a primary second carbon electrode being comprised of primary second carbon materials and being connected to the primary second positive terminal, the primary second carbon electrode having porous structures;

a primary second separator between the primary second negative electrode and the primary second carbon electrode; and

a primary second cathodic solution being within said primary second battery cell and in contact with said primary second negative electrode, said primary second separator, and said primary second carbon electrode,

wherein the primary second cathodic solution comprises a primary second solvent system and a primary second electrolyte salt,

wherein the primary second battery cell is connected to the primary first battery cell,

wherein the primary second electrode metal has a primary second melting point,

wherein the primary second battery cell has a primary second rated temperature range,

wherein the secondary first rated temperature range is higher than the primary second rated temperature range,

wherein the primary second electrode metal has a primary second electrode metal charge capacity,

wherein the primary second cathodic solution has a primary second positive charge capacity,

wherein the primary second electrode metal charge capacity is lower than the primary second positive charge capacity,

wherein the primary second battery cell is comprised of a primary second battery housing with a primary second battery headspace, and

wherein a primary second battery headspace percentage of said primary second battery housing is greater than the secondary first battery headspace percentage of said secondary first battery housing;

measuring a monitored temperature of the hybrid battery system;

generating a primary first voltage discharge level by reactions with the primary first electrode metal and the primary first cathodic solution, when the monitored temperature is within the primary first rated temperature range;

generating a primary second voltage discharge level by reactions with the primary second electrode metal and the primary second cathodic solution, when the monitored temperature is within the primary second rated temperature range;

deploying the downhole tool into a borehole;

generating a secondary first voltage discharge level by reactions with the secondary first electrode metal and the secondary first cathodic solution, when the monitored temperature is within the secondary first rated temperature range;

increasing resistance of the variable resistor to the primary battery pack with the management module before the monitored temperature is greater than the primary first rated temperature range and before the monitored temperature is greater than the primary second rated temperature range; and

stripping the primary first electrode metal from the primary first battery cell before the monitored temperature exceeds the primary first melting point; and

stripping the primary second electrode metal from the primary second battery cell before the monitored temperature exceeds the primary second melting point.

9 . The method for powering, according to claim 8 , further comprising the step of:

disconnecting the external device from said primary battery packbefore the step of increasing resistance; and

connecting said variable resistor to said primary battery pack before the step of increasing resistance.

10 . The method for powering, according to claim 8 , wherein an average primary discharge level of the primary first voltage discharge level and the primary second voltage discharge level is greater than 2.0V, the method further comprising the steps of:

decreasing the primary first voltage discharge level from greater than 2.0V;

decreasing the primary second voltage discharge level from greater than 2.0V;

increasing resistance of the variable resistor with the management module when said average primary discharge level is less than 2.0V; and

stripping the primary first electrode metal from the primary first battery cell when said average primary discharge level is less than 2.0V; and

stripping the primary second electrode metal from the primary second battery cell when said average primary voltage discharge level is less than 2.0V.