Battery charger

• US 5,043,650 A
• Filed: 02/26/1988
• Issued: 08/27/1991
• Est. Priority Date: 02/26/1988
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Watts, Fred S., Gilmore, Alan A., Bhagwat, Pradeep M.
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): Peckman, Kristine
• Application Number:
  US07/161,017
• Time in Patent Office: 1,278 Days
• Field of Search: 320/22, 320/23, 320/35, 320/36, 320/39, 320/40, 320/21, 361/103, 361/106
• US Class Current: 320/150
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/007182 in response to battery voltage
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters

Abstract

An isolated battery charger suitable for charging lead-acid batteries includes a high-frequency power conditioner that rectifies source current to a DC value and chops the current at a comparatively high frequency, e.g., 25 KHz, using a pair of MOSFET switches (138 and 140) to provide power pulses to the primary of a step-down transformer (T₁). The output of the step-down transformer (T₁) is presented to an enhancement mode MOSFET (206) in series circuit with the battery (B) to be charged with the gate bias of the MOSFET controlled in response to the sensed voltage of the battery to provide current to the battery as a function of its charge. Control circuitry is provided to limit charging to a small `trickle` level in the event the battery (B) is fully discharged to increase its charge level prior to initiating the full charge current. The provision of a voltage converter (100) operating at a relatively high frequency allows use of a lightweight and compact transformer (T₁) that nonetheless provides a high current for charging.

Claims

1. A battery charger comprising:

voltage converter means for converting a first-frequency alternating source voltage into a second-frequency alternating voltage and converting the second-frequency alternating voltage into a direct current voltage which appears at an output of the voltage converter means;

voltage controlled solid-state variable impedance means for connection between the output of the voltage converter means and a battery to be charged for controlling the flow of direct current from the output of the voltage converter means to the battery to effect charging thereof;

control means responsive to the battery voltage to provide a control voltage to said variable impedance means to charge the battery at a selected rate and to cease charging at a predetermined charge level;

the control means controls said variable impedance means to its OFF state when the voltage of the battery is below a selected value; and

wherein the variable impedance means includes a saturated region and a linear operating region in which the impedance thereof is controlled as a proportional function of the control voltage and further includes an OFF state in which the impedance is sufficiently high to cease the charging of the battery through the variable impedance means.

2. The battery charger of claim 1, wherein said variable impedance means is in series circuit with said battery and said voltage converter means.

3. The battery charger of claim 1, further comprising:

a trickle current charge path for charging the battery when said variable impedance means is in its OFF state and the voltage of the battery is below the selected value.

4. The battery charger of claim 3, wherein said trickle current charge path further comprises a light emitting diode that is forward biased when a current flows through said trickle current charge path.

5. The battery charger of claim 3, wherein said trickle current charge path is in shunt circuit with said variable impedance means.

6. The battery charger of claim 1, wherein said control means comprises:

voltage regulator means for providing the control voltage to said variable impedance means in response to a reference voltage and the voltage of the battery being charged.

7. The battery charger of claim 6, wherein said voltage regulator comprises an error amplifier for providing the control voltage to said voltage-controlled variable impedance means in response to the difference between the reference voltage and a voltage representative of the voltage of the battery being charged.

8. The battery charger of claim 1, further comprising:

temperature compensating means responsive to an increase in the temperature of said control means above a prescribed level for controlling the voltage controlled variable impedance means to thereby decrease the voltage applied to the battery as compensation for the temperature increase.

9. The battery charger of claim 1, further comprising:

temperature control means for increasing the impedance of said variable impedance means when the temperature thereof increases above a selected value.

10. The battery charger of claim 9, wherein said temperature control means decreases the impedance of said voltage variable impedance means when the temperature thereof decreases below the selected value.

11. The battery charger of claim 10, wherein said temperature control means comprises a temperature responsive resistance in heat conducting relationship with said variable impedance means.

12. The battery charger of claim 1, wherein the frequency of said second-frequency alternating voltage is between 350 and 600 times the frequency of said first-frequency alternating source voltage.

13. The battery charger of claim 1, further comprising:

a light emitting diode in circuit with said voltage controlled variable impedance and forwardly biased when said variable impedance in its saturated region.

14. The battery charger of claim 1, wherein said variable impedance means is a field effect transistor.

15. The battery charger of claim 1, further comprising a step-down transformer for stepping down said second-frequency alternating voltage.

16. The battery charger of claim 15, further comprising:

means for rectifying the stepped down second-frequency alternating voltage of said step-down transformer.

17. A battery charger comprising:

means for providing a direct current voltage for charging a battery;

voltage controlled solid-state variable impedance means for connection between the providing means and the battery to be charged for controlling the flow of current from the providing means to the battery to effect charging thereof;

control means responsive to the battery voltage to provide a control voltage to said variable impedance to charge the battery at a selected rate and to cease charging at a predetermined charge level;

wherein said variable impedance means is in series circuit with said battery and includes a saturated region and a linear operating region in which the impedance thereof is controlled as a proportional function of the control voltage and further includes an OFF state in which the impedance is sufficiently high to cease the charging of the battery, and

wherein said control means controls said variable impedance means to its OFF state when the voltage of the battery is below a selected value.

18. The battery charger of claim 17 , wherein said control means comprises:

voltage regulator means for providing the control voltage to said voltage controlled variable impedance means in response to a reference voltage and the voltage of the battery being charged.

19. The battery charger of claim 18, wherein said voltage regulator comprises an error amplifier for providing the control voltage to said voltage controlled variable impedance means in response to the difference between the reference voltage and a voltage representative of the voltage of the battery being charged.

20. The battery charger of claim 17, further comprising:

temperature control means for increasing the impedance of said variable impedance means when the temperature thereof increases above a selected value.

21. The battery charger of claim 20, wherein said temperature control means decreases the impedance of said variable impedance means when the temperature thereof decreases below the selected value.

22. The battery charger of claim 21, wherein said temperature control means comprises temperature responsive resistance in heat conducting relationship with said variable impedance means.

23. The battery charger of claim 17, further comprising:

temperature compensating means responsive to an increase in the temperature of said control means above a prescribed level for controlling the voltage controlled variable impedance means to thereby decrease the voltage applied to the battery as compensation for the temperature increase.

24. The battery charger of claim 17, further comprising:

a light emitting diode in circuit with said variable impedance means and forwardly biased when said variable impedance means is in its saturated region.

25. The battery charger of claim 17, wherein said variable impedance means is a field effect transistor.

26. A battery charger comprising:

means for providing a direct current voltage for charging a battery;

voltage controlled solid-state variable impedance means for connection between the providing means and the battery to be charged for controlling the flow of current from the providing means to the battery to effect charging thereof;

control means responsive to the battery voltage to provide a control voltage to said variable impedance to charge the battery at a selected rate and to cease charging at a predetermined charge level, and

a trickle current charge path for charging the battery when the variable impedance means is in its OFF state and the voltage of the battery is below a selected value.

27. The battery charger of claim 26, wherein said trickle current charge path is in shunt circuit with said variable impedance means.

28. The battery charger of claim 26, wherein said trickle current charge path further comprises a light emitting diode that is forward biased when a current flows through said trickle current charge path.