Executive summary
Short answer: some lithium battery faults can be repaired and many packs can be professionally refurbished, but cell-level repairs are limited and dangerous if done incorrectly. Refurbishment (testing, grading, replacing weak cells, and re-validation) is viable in controlled facilities and can extend pack life and reduce environmental impact. However, safety, cost, and regulatory factors determine whether repair/refurbishment is appropriate versus full replacement.
What "repair" and "refurbishment" mean
Repair typically refers to fixing a non-cell component (e.g., connector, fuse, BMS board) so the pack returns to safe operation. Refurbishment is a systematic process: disassembly, cell-level testing, grading, replacing weak cells/modules, reassembly, and re-certification.
Typical repairable issues
- Damaged connectors, harnesses or pack casing
- Faulty BMS firmware or board (replaceable by trained technicians)
- Loose busbars or cold solder joints
- Imbalance that can be corrected by balancing circuits or controlled top-up
Non-repairable / high-risk conditions
- Swollen cells or visible electrolyte leakage
- Evidence of internal shorting or burnt smell
- Cells with extremely high internal resistance or severe capacity loss
Refurbishment workflow (industrial best practice)
1. Intake & triage
Receive packs, document S/N, visual inspection for swelling, leakage, mechanical damage and smoke/burn marks. Discard packs that fail visual safety triage.
2. Safe discharge / discharge-to-safe-voltage
Controlled discharge to a safe voltage to reduce stored energy for disassembly. Use dedicated racks and thermal/gas monitoring.
3. Disassembly & cell extraction
Mechanized/controlled disassembly to extract modules/cells. Maintain ESD and thermal safety procedures.
4. Cell testing & grading
Measure OCV, DC internal resistance (DCIR), capacity at defined C-rate, and perform short-term cycle checks. Grade cells into A/B/C categories.
5. Replace & rebalance
Replace C-grade (or below) cells/modules with qualified spares. Rebalance modules to tight OCV/SoC spread (example: ≤ 10 mV per cell for production-class packs).
6. Reassembly & pack-level validation
Rebuild pack with new seals, install new/updated BMS if required, perform continuity, insulation, and functional tests.
7. Safety & performance re-testing
Run standardized tests: capacity check, thermal imaging under load, short-protection verification, and where needed, UN38.3 / IEC-standards subset tests before release.
| Test | Typical Acceptance | Purpose |
|---|---|---|
| Open-Circuit Voltage (OCV) | Within ±20 mV of target at given SoC | Detect cell mismatch / deep imbalance |
| DC Internal Resistance (DCIR) | Within ±10% of lot median | Identify aged or damaged cells |
| Capacity (0.2C full discharge) | ≥ 85% of nominal for A-grade | Ensure useful energy |
| Short/insulation test | Pass per pack voltage class | Safety verification |
| Thermal imaging under 1C load | No hot spots; ΔT limit per design | Check internal contact and IR mismatch |
Criteria should be tailored to the pack's application (EV traction vs. light industrial vs. consumer). Tighter criteria increase cost but improve reliability.
Refurbishment can be cost-effective and environmentally beneficial, but it is a trade-off:
| Aspect | Typical outcome |
|---|---|
| Cost vs new pack | Refurbish may be 20–50% cheaper depending on cell value & labor |
| Environmental | Extends resource use, reduces waste and mining footprint |
| Warranty & liability | Refurbished units often carry reduced warranty and require clear disclosure |
- Cell swelling, leakage, or mechanical damage
- Pack exhibits internal shorting or burning signs
- Average capacity <~70–75% of nominal (depends on application)
- Very high mismatch or spread that would require replacing large fractions of the pack
- Regulatory or warranty constraints disallow refurbishment in the target market
Refurbished packs intended for transport or sale must meet applicable regulations (UN38.3 for transport, IEC 62133 / UL standards for safety in many markets). Documentation, traceability, and clear labeling of refurbished status are mandatory in some jurisdictions.
As a manufacturer, Huawen New Power recommends:
- Design packs for maintainability (modular modules, replaceable subassemblies)
- Include BMS features that support refurbishment (cell-level logging, transport/shipping mode)
- Operate refurbishment under controlled facilities with full traceability
- Offer clear refurbished product labeling and limited warranty aligned to risk
We provide consulting, incoming cell screening, refurbishment partner referrals, and pack-level validation services.
Quick checklist: Is refurbishment right for this pack?
- Passes visual safety triage (no swelling, leakage, burns)
- Majority (>60–70%) of cells qualify as A/B grade
- Economic savings justify labor / test bench cost
- Regulatory path for re-certification exists for target market
- Traceability and warranty policy in place
FAQ (short)
Can a consumer safely refurbish their phone battery?
No — consumer-level cell replacement is risky. Use authorized service centers.
How long does a refurbished pack last?
Depends on remaining cell health and duty cycle — typically refurbishment restores meaningful life (months to years) but rarely matches a new-pack full lifetime.
Is refurbished the same as recycled?
No — refurbishment returns a pack to service; recycling breaks cells down to recover materials when reuse is no longer safe.
