MULTI-CHEMISTRY BATTERY CHARGING SYSTEM AND METHOD OF IDENTIFYING AND IMPROVED CHARGING TECHNIQUE FOR PRIMARY AND SECONDARY DRY-CELL BATTERIES

• US 20110181242A1
• Filed: 09/29/2009
• Published: 07/28/2011
• Est. Priority Date: 09/29/2008
• Status: Active Grant

• Current Assignee: Wilson Lee
• Original Assignee: Wilson Lee
• Inventors: Lee, Wilson
• Granted Patent: US 9,184,603 B2
• Time in Patent Office: Days
• US Class Current: 320/110
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries

Abstract

A microprocessor controlled multi chemistry battery charging system and method for recharging primary and secondary batteries are disclosed. The charger has multiple battery holder bays with different recess levels to accept up to four batteries of different sizes and different chemistry types particularly Primary Alkaline, Primary Titanium, Rechargeable Alkaline Manganese (RAM), NiCd and NiMH batteries. The microprocessor controlled electronic circuit automatically identifies the type of battery to be charged by monitoring and comparing voltage responses over preset time by supplying constant charging current. Depending upon the type of battery, the charger controls suitable charging current or current pulses at different frequencies till battery voltage reaches preset maximum reference voltage or battery voltage remains relatively constant below preset maximum reference voltage over preset time period. The charger has built in safety protections, battery tester function, audio visual arrangements to display status, a variable DC output port and USB ports.

Claims

1. Multi-chemistry battery charging system of identifying and improving charging technique for primary and secondary dry-cell batteries such as Alkaline or Titanium, and Rechargeable Alkaline Manganese (RAM), NiCd or NiMH, the system including:

a. a battery charger constructed to accept a variety of different sizes and different chemistry types of single dry-cell batteries,

b. a microprocessor for controlling the battery charger and

c. having electronic circuitry that can identify different primary and secondary batteries inserted into the charger and

d. applying an inherently appropriate preferred charge current and voltage to safely and properly charge up the batteries;

wherein switching circuits create charge current pulses at different frequencies to achieve the desired effects of slow, medium or fast charge rates suitable for recharging of the multi-chemistry primary and secondary dry-cell batteries within the same system.

2. Multi-chemistry battery charging system according to claim 1 wherein

the said battery charger has multiple battery holder bays that have different recess levels and sliding spring mechanisms that can secure different sized cylindrical dry-cell and prismatic sized batteries between the positive and negative charging terminals of the charger such as size AAA, AA, C or D size batteries.

3. Multi-chemistry battery charging system according to claim 2 wherein

a. each battery holder bay also has a contact means

i. that can couple with the two terminals of a battery and together with a sliding spring contact which pushes at the base of the said battery and secures the battery in place to receive the charging power.

4. Multi-chemistry battery charging system according to claim 3

a. wherein the electronic circuitry within the charger is substantially controlled by means of a single or multiple microprocessors capable of controlling and varying the supplies of the charging variable pulsing current and voltage sources applied concurrently or non-concurrently at fast medium or slow charging rates to differently identified multi-chemistry primary and secondary dry-cell batteries appropriately.

5. Multi-chemistry battery charging system according to claim 1

a. wherein the switching circuits create charge current pulses at different frequencies to achieve the desired effects of slow, medium or fast charge rates suitable for recharging of multi-chemistry battery types within the same system. including the electronic circuitry using an initial test current at preferably between 300 to 500 mA for battery identification of the multi-chemistry primary and secondary dry-cell batteries.

6. Multi-chemistry battery charging system according to claim 1

a. wherein said circuitry has multiple sub-circuits known as “

channels”

layout providing charging channels in a serial or parallel arrangement that function in unison yet independently to provide adjusted different charging currents using switching circuits to create charge current pulses at different frequencies providing the desired effects of slow, medium or fast charge rates suitable for recharging of the multi-chemistry primary and secondary dry-cell batteries within the same system.

7. Multi-chemistry battery charging system according to claim 1

a. wherein the charger is designed to accept DC and or AC power.

8. Multi-chemistry battery charging system of identifying and improved charging technique for primary and secondary dry-cell batteries such as Alkaline or Titanium, and Rechargeable Alkaline Manganese (RAM), NiCd or NiMH including the steps of:

a. Providing a battery charger with microprocessor controlled circuitry for pulsed charging of the multi-chemistry primary and secondary dry-cell batteries.

b. performing a series of self tests and initialization routines at power up of the battery charger to ensure the whole system is functioning correctly and send out appropriate signals to inform the user of its status;

c. the circuitry of the battery charger constantly sending out electrical signals to all

charging terminals to sense for the presence of batteries across all available battery bays in the battery charger;

d. upon a battery being detected as connected to the charger,

i. firstly measuring the initial voltage of the battery and comparing it with a preset range of values and deciding if the battery is a new or fully charged primary alkaline battery;

ii. if it is then promptly indicating the battery is fully charged and stopping any further processing of the said battery; and

iii. if the required condition is not met, then applying a relatively constant test current of the order between 300 to 500 mA to the battery for a preset period and monitoring the rate of voltage change of the said battery.

Wherein the electronic circuitry can identify different primary and secondary batteries inserted into the charger to allow application of an inherently appropriate preferred charge current and voltage to safely and properly charge up the batteries.

9. Multi-chemistry battery charging method of identifying and improved charging technique according to claim 8

d. wherein under relatively constant testing current, the voltage responses of most primary cells including a large percentage of rechargeable alkaline batteries and some old NiCd batteries quickly rises and meets a certain preset voltage level which allows automatic distinguishing of them as primary alkaline batteries;

and

i. these batteries would then be charged using an appropriate low to moderate charge current suitable for recharging of primary alkaline batteries until their preset full charged voltage is reached at a preferred 1.7V level

ii. and appropriate charging channels would be switched off from further processing; and

iii. suitable audio or visual signals generated to inform the user of the battery fully charged status.

10. Multi-chemistry battery charging method of identifying and improved charging technique of claim 9 wherein

e. the voltage responses that overshoot the preset abnormal voltage range would render the batteries as faulty or no longer rechargeable

i. and the appropriate charging channels would then be switched off from further processing

ii. and suitable audio or visual signals generated to inform the user of the battery bad status.

11. Multi-chemistry battery charging method of identifying and improved charging technique according to claim 8, wherein

f. for secondary rechargeable NiMH and NiCD batteries together with a certain percentage of alkaline and rechargeable alkaline batteries would have a voltage responses, from the applied relatively constant test current, rise relatively much slower and thereby automatically determine that these batteries regardless of their battery types all have in common very low internal resistances and

i. are capable of accepting fast and safe pulse or constant charging current range of the order between 300 m to 500 mA;

ii. whereby under this fast charging rate, rechargeable NiMH batteries'"'"' voltage responses would rise slowly to a preset full charged voltage range of 1.40 to 1.46V over time which varies depending on the capacity of the batteries under charge and

iii. the battery voltage would then stay relatively constant at the above voltage range over a preset period of time and

iv. when this condition is met it signals a full charged status for NiMH batteries and no further processing to the batteries are required.

12. Multi-chemistry battery charging method of identifying and improved charging technique according to claim 8 wherein

g. with the same fast charge condition applied relatively constant test current, low-internal-resistance primary alkaline and rechargeable alkaline batteries as well as NiCd'"'"'s voltage responses would rise much faster than those of NiMH described earlier and overshoot the NiMH full charged voltage range of 1.40 to 1.46V and continue to rise further and undertaking application of an inherently appropriate preferred charge current and voltage to safely and properly charge up the batteries

i. by once this limit is passed, switching the appropriate charging channels to a slow to moderate charge current suitable for charging alkaline batteries and

ii. the charging process continuing until the full charge 1.7V limit is reached.

13. Multi-chemistry battery charging method of identifying and improved charging technique according to claim 8 wherein during the whole charging process of all battery types, the controlling microprocessor(s) would sense and measure all battery voltage changes in one second increment steps and monitor for any abnormal charge responses and or charge termination criteria to occur so the charging process can be terminated promptly and all battery types are appropriately charged.

14. Multi-chemistry battery charging method of identifying and improved charging technique according to claim 8 wherein a combination of multiple charge termination and protection schemes are employed to ensure the highest safety level can be achieved that includes one or more of:

a. Alkaline battery chargesafe protection,

including the step of a gentle variable low current within a range of 30 mA up to 100 mA being used to charge and dynamically being monitored to ensure alkaline batteries being charged will not heat up and reach unsafe level;

b. Faulty battery detection &

rejection,

including the built-in microprocessor running a series of test patterns (zero voltage for dead battery and over voltage above 1.8V for bad batteries) at the beginning and at the ending of the charging process on the batteries being charged and thereby filtering out bad and dead batteries;

c. Overcharge protection,

including each battery type being pre-assigned a maximum voltage level allowable that signal full charge condition reached;

Alkaline, RAM and NiCd batteries are set at 1.7V max., NiMH is set at 1.48V max while Lithium Ion/Polymer single cell battery (3.6V/3.7V rated) is set at 4.1V max. and Lithium Ion/Polymer double cell battery (7.2V/7.4V rated) is set at 8.4V max. and when these limits for the corresponding battery types are reached, the microprocessor will terminate the charging process straight away;

d. Short circuit protection,

including the microprocessor being designed to sense short circuit conditions where an abnormal low-resistance such as a bad battery or a wire is connected between the positive and negative terminals and upon detection, the channel is turned off immediately;

e. Wrong polarity Protection,

including the micro processor sending a series of pulse currents to each channel and if the voltage response of the said channel is detected as negative voltage, this signals the battery is in reversed polarity and the charge process is terminated;

f. Negative delta voltage protection,

including while a battery is being charged, its voltage increases gradually and incrementally and this voltage is being monitored and allowed to continue to increase until it reaches the preset full voltage level according to its detected battery type and if this voltage hits a turning point and decreases noticeably then this drop means negative delta (change of) voltage has occurred and signals the battery no longer can absorb any more charge and then the charging process is terminated;

g. Zero delta voltage protection,

including while a battery is being charged, its voltage increases gradually and incrementally and this voltage is being monitored and allowed to continue to increase until it reaches the preset full voltage level according to its detected battery type and if this voltage hits a point and stays constant at this level without any further changes, this means zero delta voltage has occurred and signals the battery no longer can absorb any more charge then the charging process gets terminated and wherein zero delta voltage occurs for NiMH batteries at a voltage range of 1.44V to 1.48V and indicates it is fully charged;

h. Timer Protection,

including as a further safety backup measure, a pre-determined maximum time is set for the whole charging process to suit the battery type being charged, and once this time is reached, charging is terminated for the said battery;

i. Temperature protection via built-in cooling fan,

including whenever fast charging is employed to pump high current into the battery being charged, then the built-in fan is activated to draw out the heat generated within the internal circuitry of the charger and keep the temperature under a safe level;

j. Cooling fan failsafe protection.

Including ensuring that the built-in fan must work whenever fast charging is activated or the charger is overheated as components would become damaged; and

wherein the built-in fan is continually being monitored by the microprocessor to ensure it is working when required and if fan failure is detected, the microprocessor would inhibit fast charging from taking place and only low to medium charging is allowed which do not overheat the charger.

15. (canceled)