Multi-level automotive battery charging system

• US 5,444,352 A
• Filed: 08/02/1993
• Issued: 08/22/1995
• Est. Priority Date: 08/02/1993
• Status: Expired due to Fees

• Current Assignee: New Castle Battery Manufacturing Company
• Original Assignee: New Castle Battery Manufacturing Company
• Inventors: Hutchings, Philip P.
• Primary Examiner(s): Dougherty, Thomas M.
• Assistant Examiner(s): Ponomarenko, Nicholas
• Application Number:
  US08/101,551
• Time in Patent Office: 750 Days
• Field of Search: 320/15, 322/90
• US Class Current: 320/104
• CPC Class Codes: H01M 10/0413 Large-sized flat cells or batteries for motive or stationary systems with plate-like electrodes
• CPC Class Codes: H01M 10/0445 Multimode batteries, e.g. containing auxiliary cells or electrodes switchable in parallel or series connections
• CPC Class Codes: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H02J 7/1423 with multiple batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

An electric charging control unit is used to control charging of a dual voltage battery of an automobile electrical system. The charging control unit is used in conjunction with a standard 12 volt alternator or 12 volt charger to efficiently recharge a lead acid battery having both 12 and 16 voltage terminals. The electric charging control unit continually monitors the different voltage levels of the battery. Charging of higher voltage cells by a DC to DC converter is selectively activated when the voltage of the lower cells rises above a pre-determined voltage level. Activation of the charging of the higher voltage cells is selectively overridden in response to the voltage differential of the input and output of the DC to DC converter which are respectively coupled to the 12 and 16 volt battery terminals.

Claims

1. A multi-voltage automobile electrical system comprising:

an electric storage battery having a ground terminal and at least a first low level voltage terminal and a second high level voltage terminal;

an alternator coupled to said ground and first battery terminals for charging the low voltage level of said electric storage battery; and

a charging control unit for controlled charging of the high voltage level of said electric storage battery including;

DC to DC converter means having a low voltage input conductor coupled to said low voltage battery terminal and a high voltage output conductor coupled to said high voltage battery terminal for converting the voltage supplied at said low voltage battery terminal to a higher voltage for charging the high voltage level of the battery;

means for activating said DC to DC converter means when at least a predetermined voltage level is being supplied to said input conductor of said DC to DC converter means, said activating means gradually increases the power through said DC to DC converter to a fully activated state as the voltage level rises above said predetermined voltage level, and

means for overriding the activation of said DC to DC converter means responsive to the voltage differential between said input and output conductors of said DC to DC converter means, said override means gradually decreases the power through said DC to DC converter as the voltage differential between said input and output conductors increases.

2. A multi-voltage automobile electrical system according to claim 1, wherein:

said electric storage battery is a three terminal, lead-acid storage battery having a low 12 volt terminal, a high 16 volt terminal and a ground terminal;

said activating means gradually increases the power through said DC to DC converter to a fully activated state as the voltage level rises from 13.0 volts to 15.0 volts, and

said override means gradually decreases the power through said DC to DC converter to a minimum as the voltage differential between said input and output conductors increases to 5.4 volts.

3. An electric charging control unit for controlling the charging of an electric storage battery having a ground terminal and at least a first low level voltage terminal and a second high level voltage terminal, the battery being charged by a low voltage charging means coupled to the ground and first battery terminals, the charging control unit comprising:

DC to DC converter means having a low voltage input conductor and a high voltage output conductor for converting the voltage supplied at the low voltage battery terminal to a higher voltage for charging the high voltage level of the battery;

means for activating said DC to DC converter means when at least a predetermined voltage level is being supplied to the low voltage input conductor of said DC to DC converter said activating means gradually increases the power through said DC to DC converter to a fully activated state as the voltage level rises above said predetermined voltage level, and

means for overriding the activation of said first means responsive to the voltage differential between said input and output conductors of said DC to DC converter, said override means gradually decreases the power through said DC to DC converter as the voltage differential between said input and output conductors increases.

4. An electric charging control unit according to claim 3, wherein:

said predetermined voltage is 13.0 volts;

said activating means gradually increases the power through said DC to DC converter to a fully activated state as the voltage level rises from 13.0 volts to 15.0 volts, and

said override means gradually decreases the power through said DC to DC converter to a minimum as the voltage differential between said input and output conductors increases to 5.4 volts.

5. A combination multi-voltage electric storage battery, and electric charging control unit comprising:

an electric storage battery having a ground terminal and at least a first low level voltage terminal and a second high level voltage terminal; and

a charging control unit coupled to said first and second battery terminals for controlling the charging of the high voltage level of the battery, including;

DC to DC converter means having a low voltage input conductor and a high voltage output conductor for converting the voltage supplied at the low voltage battery terminal to a higher voltage for charging the high voltage level of the battery;

means for activating said DC to DC converter means when at least a predetermined voltage level is being supplied to the low voltage input conductor of said DC to DC converter;

said activating means gradually increases the power through said DC to DC converter to a fully activated state as the voltage level rises above said predetermined voltage level; and

means for overriding the activation of said first means responsive to the voltage differential between said input and output conductors of said DC to DC converter such that said battery is completely charged by a low voltage charging means coupled to said ground and first battery terminals, said override means gradually decreases the power through said DC to DC converter as the voltage differential between said input and output conductors increases.

6. The combination according to claim 5, wherein:

said electric storage battery is a three terminal, lead-acid storage battery having a low 12 volt terminal, a high 16 volt terminal and a ground terminal;

said activating means gradually increases the power through said DC to DC converter to a fully activated state as the voltage level rises from 13.0 volts to 15.0 volts, and

said override means gradually decreases the power through said DC to DC converter to a minimum as the voltage differential between said input and output conductors increases to 5.4 volts.