Method and apparatus for charging a rechargeable battery

• US 5,994,878 A
• Filed: 09/15/1998
• Issued: 11/30/1999
• Est. Priority Date: 09/30/1997
• Status: Expired due to Fees

• Current Assignee: Star Werks Inc.
• Original Assignee: Chartec Laboratories A/S
• Inventors: Nielsen, Otto Martinus, Rasmussen, Kim, Stuck Andersen, Kim Arthur, Ostergaard, Kim, Michelsen, Jesper
• Primary Examiner(s): Tso, Edward H.
• Application Number:
  US09/153,126
• Time in Patent Office: 441 Days
• Field of Search: 320/124, 320/125, 320/132, 320/134, 320/136, 320/DIG. 18, 320/DIG. 19, 320/DIG. 21
• US Class Current: 320/132
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H02J 7/0071 with a programmable schedule

Abstract

In a system and method for charging a rechargeable battery having a protection circuit, the rechargeable battery operates according to a model that includes an ideal battery and an internal resistance. In the model, an electrode voltage develops across the ideal battery. An internal voltage drop equal to the difference between this electrode voltage and the battery voltage is developed across the internal resistance. The battery is charged with a charging voltage that may exceed the threshold voltage and the electrode voltage. The charging system and method ensures that (1) the voltage at the protection circuit is kept below the threshold voltage and (2) the electrode voltage is kept below the end-of-charge voltage.

Claims

1. A method of charging a rechargeable battery, the method comprising:

(a) providing a battery pack comprising;

(1) a plurality of terminals for accepting a charging current, a first voltage being developed across the terminals;

(2) a rechargeable battery, coupled to the terminals, a second voltage being developed across the rechargeable battery, the rechargeable battery operating according to a model comprising;

(A) an ideal battery, a third voltage being developed across the ideal battery, the third voltage reaching an end-of-charge voltage when the rechargeable battery is fully charged, and

(B) an internal resistance, a voltage differential between the second voltage and the third voltage being developed across the internal resistance in proportion to the charging current; and

(3) a protection circuit, coupled to the rechargeable battery, for causing charging current to be stopped whenever the second voltage reaches a threshold voltage; and

(b) supplying charging current so as to maintain the second voltage to be above the end-of-charge voltage and to be below the threshold voltage during at least part of the charging process;

whereby the rechargeable battery is charged without the protection circuit causing charging current to be stopped.

2. The method of claim 1 wherein the battery pack provides the value of the threshold voltage from an information storage device contained in the battery pack.

3. The method of claim 1 further comprising, before step (b), supplying charging current at a predetermined constant current rate.

4. The method of claim 3 wherein the constant current rate is about 1-2 times the constant current rate that would charge the rechargeable battery in one hour.

5. The method of claim 3 wherein the battery pack provides the value of the constant current rate from an information storage device contained in the battery pack.

6. The method of claim 1 further comprising supplying charging current to maintain the third voltage to be at or below the end-of-charge voltage.

7. The method of claim 6 wherein the battery pack provides the value of the end-of-charge voltage from an information storage device contained in the battery pack.

8. The method of claim 1 further comprising, after step (b), terminating charging when the charging current falls below a lower limit, the lower limit being in the range from about 5% to about 20% of the constant charging current.

9. The method of claim 1 further comprising a process for measuring the second voltage using a voltage detection circuit, the process comprising:

(1) providing a voltage detection circuit for measuring the second voltage;

(2) charging the rechargeable battery in an initial charging phase; and

(3) calibrating the output of the voltage detection circuitry using the result of the calibration.

10. The method of claim 1 further comprising supplying charging current so as to maintain the first voltage to be at or below a maximum charging voltage.

11. The method of claim 10 wherein the maximum charging voltage is a function of:

(1) the end-of-charge voltage;

(2) the charging current; and

(3) the internal resistance.

12. The method of claim 10 wherein the battery pack provides the value of the maximum charging voltage from an information storage device contained in the battery pack.

13. The method of claim 1 further comprising a process for measuring the third voltage, the process comprising:

(1) repeatedly interrupting the supply of significant charging current;

(2) while significant charging current is interrupted, measuring an open-circuit voltage across the terminals; and

(3) resupplying charging current to the terminals to maintain the third voltage to be below the end-of-charge voltage.

14. The method of claim 1 wherein the rechargeable battery comprises a plurality of cells and the protection circuit is further coupled to a plurality of cells.

15. A method of charging a rechargeable battery, the method comprising, in sequence:

(a) providing a battery pack comprising;

(1) a plurality of terminals for accepting a charging current, a first voltage being developed across the terminals;

(2) a rechargeable battery, coupled to the terminals, a second voltage being developed across the rechargeable battery, the rechargeable battery operating according to a model comprising;

(A) an ideal battery, a third voltage being developed across the ideal battery, the third voltage reaching an end-of-charge voltage when the rechargeable battery is fully charged, and

(B) an internal resistance, a voltage differential between the second voltage and the third voltage being developed across the internal resistance in proportion to the charging current; and

(3) a protection circuit, coupled to the rechargeable battery, for causing charging current to be stopped whenever the second voltage reaches a threshold voltage;

(b) supplying charging current at a constant current rate of about 1-2 times the amount of current that would charge the rechargeable battery in one hour;

(c) supplying charging current so as to maintain the first voltage to be at or below a maximum charging voltage;

(d) supplying charging current so as to maintain the second voltage to be above the end-of-charge voltage and to be below the threshold voltage;

(e) supplying charging current to maintain the third voltage to be at or below the end-of-charge voltage; and

(f) terminating charging when the charging current falls below a lower limit, the lower limit being in the range from about 5% to about 20% of the constant charging current;

whereby the rechargeable battery is charged without the first voltage exceeding the maximum charging voltage, the second voltage exceeding the threshold voltage of the protection circuit, or the third voltage exceeding the end-of-charge voltage.

16. The method of claim 15 further comprising a process for measuring the second voltage using a voltage detection circuit, the process comprising:

(1) providing a voltage detection circuit for measuring the second voltage;

(2) charging the rechargeable battery in an initial charging phase; and

(3) calibrating the output of the voltage detection circuitry using the result of the calibration.

17. The method of claim 15 further comprising a process for measuring the third voltage, the process comprising:

(1) repeatedly interrupting the supply of significant charging current;

(2) while significant charging current is interrupted, measuring an open-circuit voltage across the terminals; and

(3) resupplying charging current to the terminals to maintain the third voltage to be below the end-of-charge voltage.

18. The method of claim 15 wherein the maximum charging voltage is a function of:

(1) the end-of-charge voltage;

(2) the charging current; and

(3) the internal resistance.

19. The method of claim 15 wherein the battery pack provides the values of a plurality of the maximum charging voltage, the constant current rate, the threshold voltage, and the end-of-charge voltage from an information storage device contained in the battery pack.

20. The method of claim 15 wherein the rechargeable battery comprises a plurality of cells and the protection circuit is further coupled to a plurality of cells.

23. The system of claim 18 wherein the charging process further comprises, before step (b)(1), supplying charging current at a predetermined constant current rate.

24. The system of claim 23, wherein the charger supplies constant charging current at about 1-2 times the rate that would charge the rechargeable battery in one hour.

25. The system of claim 23 further comprising an information storage device in the battery pack for providing the value of the constant current rate.

21. A system for charging a rechargeable battery, the system comprising:

(a) a battery pack including;

(1) a plurality of terminals for accepting a charging current, a first voltage being developed across the terminals;

(2) a rechargeable battery, coupled to the terminals, a second voltage being developed across the rechargeable battery, the rechargeable battery operating according to a model comprising;

(A) an ideal battery, a third voltage being developed across the ideal battery, the third voltage reaching an end-of-charge voltage when the rechargeable battery is fully charged, and

(B) an internal resistance, a voltage differential between the second voltage and the third voltage being developed across the internal resistance in proportion to the charging current; and

(3) a protection circuit, coupled to the rechargeable battery, for causing charging current to be stopped whenever the second voltage reaches a threshold voltage; and

(b) a charger for supplying charging current in a charging process, the charging process comprising maintaining the second voltage to be above the end-of-charge voltage and to be below the threshold voltage during at least part of the charging process;

whereby the charger charges the rechargeable battery without the protection circuit causing charging current to be stopped.

22. The system of claim 21 further comprising an information storage device in the battery pack for providing the value of the threshold voltage.

26. The system of claim 21 wherein the charging process further comprises supplying charging current so as to maintain the first voltage to be at or below a maximum charging voltage.

27. The system of claim 26 further comprising an information storage device in the battery pack for providing the value of the maximum charging voltage to the charger.

28. The system of claim 21 wherein the charger determines the maximum charging voltage responsive to:

(1) the end-of-charge voltage;

(2) the charging current; and

(3) the internal resistance.

29. The system of claim 21 wherein the charging process further comprises supplying charging current to maintain the third voltage to be at or below the end-of-charge voltage.

30. The system of claim 29 further comprising an information storage device in the battery pack for providing the value of the end-of-charge voltage.

31. The system of claim 21 wherein the charging process further comprises terminating charging when the charging current falls below a lower limit, the lower limit being in the range from about 5% to about 20% of the constant charging current.

32. The system of claim 21 wherein the charging process further comprises a measuring process for measuring the third voltage, the measuring process comprising:

(1) repeatedly interrupting the supply of significant charging current;

(2) while significant charging current is interrupted, measuring an open-circuit voltage across the terminals; and

(3) resupplying charging current to the terminals to maintain the third voltage to be below the end-of-charge voltage.

33. The system of claim 21 further comprising a voltage detection circuit for measuring the second voltage, the output of the voltage detection circuitry being calibrated by charging the rechargeable battery in an initial charging phase.

34. The system of claim 21 wherein the rechargeable battery comprises a plurality of cells and the protection circuit is further coupled to a plurality of cells.

35. A system for charging a rechargeable battery, the system comprising:

(a) a battery pack comprising;

(1) a plurality of terminals for accepting a charging current, a first voltage being developed across the terminals;

(2) a rechargeable battery, coupled to the terminals, a second voltage being developed across the rechargeable battery, the rechargeable battery operating according to a model comprising;

(A) an ideal battery, a third voltage being developed across the ideal battery, the third voltage reaching an end-of-charge voltage when the rechargeable battery is fully charged, and

(B) an internal resistance, a voltage differential between the second voltage and the third voltage being developed across the internal resistance in proportion to the charging current; and

(3) a protection circuit, coupled to the rechargeable battery, for causing charging current to be stopped whenever the second voltage reaches a threshold voltage;

(b) a charger for supplying charging current in a charging process, the charging process comprising;

(1) supplying a constant charging current at a rate of about 1-2 times the amount of current that would charge the rechargeable battery in one hour;

(2) supplying charging current so as to maintain the first voltage to be at or below a maximum charging voltage;

(3) supplying charging current so as to maintain the second voltage to be above the end-of-charge voltage and to be below the threshold voltage;

(4) supplying charging current to maintain the third voltage to be at or below the end-of-charge voltage; and

(5) terminating charging when the charging current falls below a lower limit, the lower limit being in the range from about 5% to about 20% of the constant charging current;

whereby the charger charges the rechargeable battery without allowing the first voltage to exceed the maximum charging voltage, without allowing the second voltage to exceed the threshold voltage of the protection circuit, and without allowing the third voltage to exceed the end-of-charge voltage.

36. The system of claim 35 further comprising a voltage detection circuit for measuring the second voltage, the output of the voltage detection circuitry being calibrated by charging the rechargeable battery in an initial charging phase.

37. The system of claim 35 wherein the charging process further comprises a measuring process for measuring the third voltage, the measuring process comprising:

(1) repeatedly interrupting the supply of significant charging current;

(2) while significant charging current is interrupted, measuring an open-circuit voltage across the terminals; and

(3) resupplying charging current to the terminals to maintain the third voltage to be below the end-of-charge voltage.

38. The system of claim 35 wherein the maximum charging voltage is a function of:

(1) the end-of-charge voltage;

(2) the charging current; and

(3) the internal resistance.

39. The system of claim 35 wherein the battery pack provides the values of a plurality of the maximum charging voltage, the constant current rate, the threshold voltage, and the end-of-charge voltage from an information storage device contained in the battery pack.

40. The system of claim 35 wherein the rechargeable battery comprises a plurality of cells and the protection circuit is further coupled to a plurality of cells.

41. The system of claim 35 wherein the battery pack provides the values of a plurality of the maximum charging voltage, the constant current rate, the threshold voltage, and the end-of-charge voltage from an information storage device contained in the battery pack.

42. A system for charging a rechargeable battery, the system comprising:

(a) a battery pack including

(1) a plurality of terminals for accepting a charging current specified not to exceed a maximum charging current, a first voltage specified not to exceed a maximum charging voltage being developed across the terminals;

(2) a rechargeable battery, coupled to the terminals, a second voltage being developed across the rechargeable battery, the rechargeable battery operating according to a model comprising;

(A) an ideal battery, a third voltage specified not to exceed an end-of-charge voltage being developed across the ideal battery, the end-of-charge voltage being developed across the ideal battery when the rechargeable battery is fully charged,

(B) an internal resistance, a voltage differential between the second voltage and the third voltage being developed across the internal resistance in proportion to the charging current, and

(C) an information storage device for storing a plurality of charging parameters; and

(b) a battery charger for charging the rechargeable battery, the charger including an information receiver for receiving the charging parameters, the charger controlling the charging of the rechargeable battery in accordance with the plurality of charging parameters.

43. The system of claim 42, wherein the charging parameters include the charging current, specified not to exceed a maximum charging current.

44. The system of claim 42, wherein the charging parameters include the first voltage, specified not to exceed a maximum charging voltage.

45. The system of claim 42, wherein the charging parameters include the third voltage, specified not to exceed an end-of-charge voltage.

46. The system of claim 42, wherein the battery pack further includes a protection circuit, coupled to the rechargeable battery, for causing charging current to be stopped whenever the second voltage reaches a threshold voltage, and wherein the charging parameters include the threshold voltage.

47. The system of claim 42, wherein the information storage device comprises a resistor network.

48. The system of claim 42, wherein the information storage device comprises a non-volatile electronic memory device.