Universal battery charger and method

• US 5,686,808 A
• Filed: 05/31/1995
• Issued: 11/11/1997
• Est. Priority Date: 05/31/1995
• Status: Expired due to Fees

• Current Assignee: Frank T. Lutz
• Original Assignee: Frank T. Lutz
• Inventors: Lutz, Frank T.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): Law, Patrick B.
• Application Number:
  US08/454,703
• Time in Patent Office: 895 Days
• Field of Search: 320/2, 320/32, 320/35, 320/5, 320/20, 320/15
• US Class Current: 320/110
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H02J 7/00043 using switches, contacts or markings, e.g. optical, magnetic or barcode
• 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
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

Apparatus for charging a battery includes a charger main body having a docking station with a docking bed and programmable electronics, which includes an array of programming contacts exposed at the docking bed, and a docking tray mountable on the docking bed. The docking tray has electrical contacts for interconnecting with at least one type and size of battery and an array of contactors connected with the electrical contacts, which contact selected ones of the programming contacts, and include associated circuitry on the tray to program the electronics for charging of the battery. Further, a method provides the steps of using a tray or a bed of the main charger body to engage contactors exposed on the tray with contacts exposed on the bed and connected to the circuitry of the main charger body, determining charging parameters for charging a battery of a particular type and size using charging circuitry in the tray complementary to the circuitry of the main charger body, connecting the battery to be charged to the circuit of the tray, and executing an automatic charging process.

Claims

1. An apparatus for charging rechargeable batteries of differing types and sizes, comprising:

a charger main body comprising a docking station including

a docking bed and

programmable electronics including an array of contacts exposed at the docking bed;

a first docking tray engageable with the docking bed and including

means for connecting a rechargeable battery of one type and size to a pair of electrical battery contacts and

an array of contactors at least two of which are connected with the pair of electrical battery contacts, the array of contactors and associated circuitry being arranged on a surface of the first docking tray to contact, upon engagement of the first docking tray with the docking bed, the array of exposed contacts to program the programmable electronics for charging of the rechargeable battery.

2. The apparatus for recharging rechargeable batteries according to claim 1, further including a second docking tray interchangeable with the first docking tray, the first and second docking trays and the main charger body being portable together.

3. The apparatus for recharging rechargeable batteries according to claim 1, further including a plurality of additional docking trays interchangeable with the first docking tray, the first docking tray, the plurality of additional docking trays, and the main charger body being portable together and providing adaptability for charging a plurality of additional batteries respectively differing from each other and from the battery of one type and size.

4. The apparatus for recharging rechargeable batteries according to claim 1, further including

means for providing snappable engagement of the docking tray with the docking bed.

5. The apparatus for recharging rechargeable batteries according to claim 1, wherein

the docking tray has a plurality of battery connecting means for connecting to one of the batteries of differing types and sizes and the array of contactors include a pair of contactors interconnected with each of the plurality of the connecting means.

6. The apparatus for recharging rechargeable batteries according to claim 3, further including

means on each one of the trays for connecting a respective one of the plurality of batteries to the pair of electrical battery contacts.

7. The apparatus for recharging a rechargeable battery according to claim 6, wherein the respective battery is mounted on the one tray.

8. The apparatus for recharging rechargeable batteries according to claim 1, further including means responsive to a selection by the user for partially discharging the battery prior to commencement of charging.

9. The apparatus for recharging rechargeable batteries according to claim 1, wherein

the docking tray includes means for sensing a temperature of the battery to produce a temperature signal and

the programmable electronics of the docking station includes means for determining a rate of change of the temperature of the battery in response to the temperature signal and means for determining the rate of charging of the battery at least partly in relation to the determined rate of change of temperature of the battery,

the sensing means being connected to the charge rate determining means through one of the exposed contacts of the docking station.

10. The apparatus for recharging rechargeable batteries according to claim 9, wherein a respective one of the array of contactors contacts the one exposed contact through which the sensing means is connected to the charge rate determining means, and means for adapting the sensed signal for the respective battery is connected to the respective one contactor.

11. The apparatus for recharging a rechargeable battery according to claim 1, wherein

the docking tray includes means for sensing terminal voltage of the battery and

the programmable electronics of the docking station includes means for determining a rate of change of the terminal voltage of the battery and means for determining the rate of charging of the battery at least partly in relation to the determined rate of change of terminal voltage of the battery,

the voltage sensing means being connected to the charge rate determining means through one of the exposed contacts of the docking station.

12. The apparatus for recharging rechargeable batteries according to claim 11, wherein a respective one of the array of contactors contacts the one exposed contact through which the voltage sensing means is connected to the charge rate determining means, and means for adapting the sensed signal for the respective rechargeable battery is connected to the respective one contactor.

13. The apparatus for recharging a rechargeable battery according to claim 1, wherein

the first docking tray includes means for sensing a temperature of the battery and

the programmable electronics of the docking station includes means for determining the rate of change of the temperature of the battery and means for determining the rate of charging of the battery at least partly in relation to the determined rate of change of temperature of the battery,

the temperature sensing means being connected to the charge rate determining means through one of the docking station programming contacts, and

wherein still further

the docking tray includes means for sensing terminal voltage of the battery and

the docking station programmable electronics includes means for determining the rate of change of the terminal voltage of the battery and means for determining the rate of charging of the battery, as a backup for the determined temperature charge rate, at least partly in relation to the determined battery terminal voltage charge rate,

the means for sensing terminal voltage being connected to the battery terminal voltage charge rate determining means through a second contact of the docking station programming contacts.

14. An apparatus for rapidly charging a battery comprising:

temperature sensing means, coupled to the battery, for sensing and producing a signal responsive to a temperature of the battery;

signal means, connected to the temperature sensing means, for providing a signal representative of a rate of change of the temperature;

charge control means, connected to the signal means and including first and second charging circuits, the first charging circuit being adapted to charge the battery at a first rate when the signal from the signal means is below a predetermined amplitude, the second charging circuit being adapted to charge the battery at a second rate when the signal is above the predetermined amplitude,

wherein;

a docking station having a docking bed and exposed contacts in the docking bed contains the signal means and the charge control means and

a docking tray, adapted to releasably engage the docking bed, receives the rechargeable battery, contains the temperature sensing means, and provides electrical connections and electrical circuits from the battery to electrical contactors that engage a plurality of the exposed contacts to connect the first charging circuit to the battery and the second charging circuit to the battery and thereby to determine the first and second charging rates for the battery when the docking tray is engaged with the docking bed of the docking station.

15. The apparatus for rapidly charging a battery according to claim 14, further including:

means for providing snappable engagement of the docking tray with the docking bed.

16. The apparatus for rapidly charging a battery according to claim 14, wherein:

the docking tray has a plurality of battery connecting means for receiving at respective sets of contacts respective ones of the batteries; and

the array of contactors includes a pair of contactors interconnected with each of the respective sets of contacts.

17. The apparatus for rapidly charging a battery according to claim 14, further including:

a plurality of additional docking trays portable with the main charger body and the first docking tray, each of the additional docking trays being individually engageable with the docking bed and including

an array of contactors, a pair of which are arranged to be connected with the battery, the array of contactors being arranged on an exterior surface of the tray to contact, upon engagement of the first tray with the docking bed, the exposed contacts.

18. The apparatus for rapidly charging a battery according to claim 14, wherein:

a plurality of the first and additional docking trays are adapted for Li/Li-ion batteries and for NiMH batteries.

19. The apparatus for rapidly charging a battery according to claim 14, further including means responsive to a selection by the user for partially discharging the battery prior to commencement of charging.

20. The apparatus for rapidly charging a battery according to claim 14, wherein:

the docking tray includes means for sensing terminal voltage of the battery and

the electronics of the docking station includes means for determining a rate of change of the terminal voltage of the battery and means for determining a rate of charging of the battery at least partly in relation to the determined rate of change of terminal voltage of the battery,

the means for sensing being connected to the means for determining through one of the exposed contacts of the docking station.

21. The apparatus for rapidly charging a battery according to claim 20, wherein:

the means for determining the rate of change of terminal voltage is subordinated to and is used as a backup for the means for sensing the temperature of the battery and the means for providing the signal representative of the rate of change of the temperature.

22. A method of charging a battery with a charger including a main charger body with charging circuitry having elements usable for charging a plurality of batteries of different types and sizes, the method comprising the steps of:

engaging a docking tray with a docking bed of the main charger body to engage contactors exposed on the tray with contacts exposed on the bed and connected to the circuitry of the main charger body, the tray including charging circuitry complementary to the circuitry of the main charger body and selected to determine charging parameters for charging a battery of a particular type and size;

connecting the battery to be charged to the charging circuitry of the tray; and

executing an automatic charging process.

23. The method of charging a battery according to claim 22, wherein

the circuitry of the tray includes sensing circuitry for generating a first signal indicating charging of the battery,

the circuitry of the main charger body includes circuitry for generating a second signal indicating a rate of change of the first signal, and

the step of executing the automatic charging process includes the steps of generating the first signal and generating the second signal.

24. The method of charging a battery according to claim 23, wherein

the step of generating the first signal comprises steps of sensing a temperature associated with the battery and generating a signal indicative of the temperature.

25. A method of rapidly charging a battery comprising the steps of:

sensing the temperature of the battery and producing from that sensing an electrical signal representative of the rate of change of sensed temperature;

applying a charging current of a first level to the battery as long as the produced electrical signal remains below a predetermined value and reducing the charging current when the new electrical signal exceeds the predetermined value;

determining the first level of charging current in dependence upon a charging parameter, the charging parameter being determined by a docking tray having a first array of contacts engageable with a second array of contacts of a charger main body, the charger main body having a docking station including a docking bed with which the docking tray engages and at which the second array of contacts are exposed, engagements of the first and second arrays of contacts occurring when the tray is engaged with the bed; and

engaging the docking tray with the docking bed.

26. The method of rapidly charging a battery according to claim 25, wherein:

the step of applying a charging current is preceded by a step of discharging the battery partially in dependence on the type of battery.

27. The method of rapidly charging a battery according to claim 26, wherein:

the step of discharging the battery depends in part upon a circuit parameter associated with a particular type and size of the battery.

28. The method of rapidly charging a battery according to claim 26, wherein:

the step of discharging the battery depends in part upon and includes a step of evaluating a selection by the user.

29. The method of rapidly charging a battery according to claim 25, wherein:

the step of applying a charging current further includes a step of determining a rate of change of terminal voltage and evaluating that rate of change of voltage in relation to the rate of change of temperature.

30. The method of rapidly charging a battery according to claim 29, wherein:

the step of determining a rate of change of terminal voltage and evaluating that rate of change of voltage is affected by a parameter associated with a particular type and size of the battery.

31. The method of rapidly charging a battery according to claim 25, further including the step of determining the need for and amount of charging current to maintain a charged condition of the battery.

32. The method of rapidly charging a battery according to claim 31, wherein the step of determining the need for and amount of charging current to maintain a charged condition depends at least in part on a parameter associated with a particular type and size of the battery.