Our Approach to Rebuilding Hybrid Battery Packs Produces a Reliable Alternative to Factory-New Batteries

Rather than boasting a “proprietary” process, the DC Battery Hub approach to rebuilding Hybrid Electric Vehicle battery packs is precise, independently standardized and validated for efficacy.

Every “donor” battery pack received by DC Battery Hub is inspected for its quality, cleaned, and prepared for rebuilding. Then, the battery cells are cycled (conditioned), analyzed and screened: taken precisely to their lowest healthy state of charge, recharged to their highest capacity, and then re-balanced to the original state-of-charge specifications. Only the best cells are kept; others are properly recycled.

After a sufficient number of high-quality conditioned cells are available they are reinstalled into the Hybrid battery chassis and evenly balanced to achieve an equal state of charge among all of the cells. The final battery product is then shipped to the installer for delivery to the end-customer.

DC Battery Hub utilizes technology created by Dr. Mark Quarto of QTS, LLC. and is distributed by FutureTech, a vehicle Electrification Technology solutions provider.

Teardown

Each core is disassembled down to it's component parts. Each component is checked for integrity—the good parts get cleaned and stored and the bad parts get properly recycled.

Cleaning

All module packs get vacuumed; terminals are cleaned with vinegar and a wire brush; the pack gets washed with a degreaser and then they are dried off with compressed air.

Brick Assembly

To maximize our equipment, we process the modules in bricks of twenty.

Discharging

Modules are discharged to the lowest state of charge (SOC) level recommended by OE.

Charging

Modules are then charged to 100% to extend their capacity.

Thermal Testing

Every module is checked during the charging process for higher than normal core temperatures. Any module that shows up red on the thermal meter is considered scrap and properly recycled.

Power Testing

Modules are run through a power (stress) test which determines the amount of energy a module can give on demand. If they don't meet the minimum level, they are deemed bad and are properly recycled.

Self-Discharge

The modules are stored for a period of time and then a measurement is taken of the energy that has been lost during this period. If the module has more energy lost than the maximum level set, it is deemed bad and properly recycled.

Balancing

After the modules are run through our process, we then balance them to a common state of charge. All the common grades are put into a pack so that the battery is balanced and ready for sale.

Final Assembly

The balanced pack, clean bus bars and the rest of the components needed for an assembly are then assembled for shipping.

Shipping

All units are packed into returnable dunnage (containers).