Battery charger

• US 6,476,585 B1
• Filed: 03/05/2001
• Issued: 11/05/2002
• Est. Priority Date: 09/03/1998
• Status: Expired due to Fees

• Current Assignee: Neil S. Simmonds
• Original Assignee: Neil S. Simmonds
• Inventors: Simmonds, Neil S.
• Primary Examiner(s): TOATLEY, GREGORY J
• Application Number:
  US09/786,705
• Time in Patent Office: 610 Days
• Field of Search: 320/134, 320/162, 320/163, 320/164
• US Class Current: 320/162
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters

Abstract

A charging circuit and method for charging a lithium-ion cell or battery at a charging voltage that is varied during the charging of the cell or battery from a selected minimum charging voltage to a predetermined maximum charging voltage. The charging circuit includes a transformer for transforming line voltage applied to the primary winding thereof to a lower AC secondary winding voltage, the transformer being selected to limit secondary winding output current when the charging voltage is not less than the selected minimum charging voltage to a value not exceeding a selected upper limit for the lithium-ion cell; a rectifier sub-circuit connected to the secondary winding of the transformer for rectifying the secondary winding voltage; and a charge-voltage regulator sub-circuit connected to the rectifier sub-circuit for receiving the rectified secondary winding voltage and providing an output charging voltage that is limited to the predetermined maximum charging voltage.

Claims

1. A charging circuit for charging a lithium-ion cell or battery (335, 435) at a charging voltage that varies during the charging of the cell or battery (335, 435) from a selected minimum charging voltage to a predetermined maximum charging voltage, comprising:

(a) a selected suitable transformer (305, 405) for transforming AC line voltage applied to the primary winding (303, 403) thereof to a lower AC secondary winding voltage;

(b) a rectifier sub-circuit (309, 409) connected to the secondary winding (307, 407) of the transformer (305, 405) for rectifying the secondary winding voltage; and

(c) a charge-voltage regulator sub-circuit (323, 423) connected between the rectifier sub-circuit (309, 409) and the lithium-ion cell or battery (335, 435) for receiving the rectified secondary winding voltage and providing an output charging voltage that is limited to the predetermined A maximum charging voltage;

the charge-voltage regulator sub-circuit (323, 423) being connectable to the lithium-ion cell or battery (335, 435) for charging the lithium-ion cell or battery (335, 435) by applying the output charging voltage across the lithium-ion cell or battery (335, 435);

wherein

(d) the charging circuit in operation provides charging current to the cell or battery (335, 435) in two successive stages, viz

(i) a first stage, during which the charge-voltage regulator sub-circuit (323, 423) operates in non-regulating mode thereby to apply output charging voltage across the lithium-ion cell or battery (335, 435) at a value below the predetermined maximum charging voltage; and

(ii) a second stage, during which the charge-voltage regulator sub-circuit (323, 423) operates in a voltage-regulating mode thereby to apply output charging voltage across the lithium-ion cell or battery (335, 435) at a value limited to the predetermined maximum charging voltage;

and wherein the charge-voltage regulator sub-circuit (323, 423) changes its mode of operation from non-voltage-regulating mode to voltage-regulating mode when the voltage charging voltage across the lithium-ion cell or battery (335, 435) reaches the predetermined maximum charging voltage;

further characterized in that

(e) the transformer (305, 405) is selected to limit secondary winding output current when the charging voltage is greater than the selected minimum charging voltage so that the secondary winding output current will not exceed a selected upper limit for the lithium-ion cell (335, 435);

(f) the charge-voltage regulator sub-circuit (323, 423) is connected to the rectifier sub-circuit (309, 409) for receiving the rectified secondary winding voltage; and

(g) wherein when the charge-voltage regulator sub-circuit (323, 423) operates in non-voltage-regulating mode, the charge circuit provides charging current to the cell or battery which is limited by means of the loading effect of the transformer (305, 405).

2. The charging circuit of claim 1, additionally comprising a smoothing sub-circuit (311, 411) connected between the rectifier sub-circuit (309, 409) and the charge-voltage regulator sub-circuit (323, 423) for smoothing the rectified secondary winding voltage supplied to the charge-voltage regulator sub-circuit (323, 423).

3. The charging circuit of claim 2, characterized in that the transformer (305, 405) is selected on the basis that the AC line voltage applied to the primary winding thereof is a predetermined maximum AC line voltage.

4. The charging circuit of claim 1, characterized in that the transformer (305, 405) is selected on the basis that the AC line voltage applied to the primary winding thereof is a predetermined maximum AC line voltage.

5. The charging circuit of claim 1, wherein the transformer is selected on the basis that the AC line voltage applied to the primary winding thereof is a predetermined maximum AC line voltage.

6. The charging circuit of claim 5, wherein the minimum charging voltage is selected to be approximately equal to the average of (1) the initial charging voltage of the lithium-ion cell or when the charging current is held at a constant level equal to the 1.0 C rate for the lithium-ion cell or battery and (2) the predetermined nominal voltage of the lithium-ion cell or battery.

7. The charging circuit of claim 5 for a single lithium-ion cell, wherein the minimum charging voltage is approximately 3.6 volts.

8. The charging circuit of claim 7, wherein the upper current limit is selected to be not greater than the maximum rate for the lithium-ion cell or battery specified by the manufacturer of the lithium-ion cell or battery.

9. The charging circuit of claim 5, wherein the upper current limit is selected to be not less than the 0.5 C rate nor greater than the 1.0 C rate for the lithium-ion cell or battery.

10. The charging circuit of claim 5, wherein the upper current limit is selected to be approximately the 1.0 C rate for the lithium-ion cell or battery.

11. The charging circuit of claim 5, wherein the charge voltage regulator sub-circuit comprises a selected suitable charge-control IC device whose input terminal is connected to the positive output terminal of the rectifier sub-circuit, and whose output terminal is connected to the positive terminal of the lithium-ion cell or battery to be charged, and whose ground terminal is connected to the negative terminal of the rectifier sub-circuit and to the negative terminal of the lithium-ion cell or battery to be charged.

12. The charging circuit of claim 11, wherein the charge control IC device is of the low drop-out voltage type.

13. The charging circuit of claim 5, wherein the charge voltage regulator sub-circuit comprises a selected suitable charge-control IC device whose input terminal is connected to the positive output terminal of the rectifier sub-circuit, and whose output terminal is connected to the positive terminal of the lithium-ion cell or battery to be charged, and whose adjustment terminal is connected to one terminal of an adjustable resistor whose other terminal is connected to the negative terminal of the rectifier sub-circuit and to the negative terminal of the lithium-ion cell or battery to be charged, the adjustment terminal also being connected to one terminal of a resistor whose other terminal is connected to the output terminal of the IC device.

14. The charging circuit of claim 13, wherein the charge control IC device is of the low drop-out voltage type.

15. A charging circuit for charging a lithium-ion cell or battery at a charging voltage that varies during the charging of the cell or battery from a selected minimum charging voltage to a predetermined maximum charging voltage, comprising:

(a) a selected suitable transformer for transforming AC line voltage applied to the primary winding thereof to a lower AC secondary winding voltage;

(b) a rectifier sub-circuit connected to the secondary winding of the transformer for rectifying the secondary winding voltage; and

(c) a charge-voltage regulator sub-circuit connected between the rectifier sub-circuit and the lithium-ion cell or battery for receiving the rectified secondary winding voltage and providing an output charging voltage that is limited to the predetermined maximum charging voltage;

the charge-voltage regulator sub-circuit being connectable to the lithium-ion cell or battery for charging the lithium-ion cell or battery by applying the output charging voltage across the lithium-ion cell or battery;

wherein

(d) the charging circuit in operation provides charging current to the cell or battery in two successive stages, viz;

(i) a first stage, during which the charge-voltage regulator sub-circuit operates in non-regulating mode thereby to apply output charging voltage across the lithium-ion cell or battery at a value below the predetermined maximum charging voltage; and

(ii) a second stage, during which the charge-voltage regulator sub-circuit operates in a voltage-regulating mode thereby to apply output charging voltage across the lithium-ion cell or battery at a value limited to the predetermined maximum charging voltage;

(e) wherein the charge-voltage regulator sub-circuit changes its mode of operation from non-voltage-regulating mode to voltage-regulating mode when the voltage charging voltage across the lithium-ion cell or battery reaches the predetermined maximum charging voltage;

(f) the transformer is selected to limit secondary winding output current when the charging voltage is greater than the selected minimum charging voltage so that the secondary winding output current will not exceed a selected upper limit for the lithium-ion;

(g) the charge-voltage regulator sub-circuit is connected to the rectifier sub-circuit for receiving the rectified secondary winding voltage;

(h) when the charge-voltage regulator sub-circuit operates in non-voltage-regulating mode, the charge circuit provides charging current to the cell or battery that is limited by means of the loading effect of the transformer; and

(i) the minimum charging voltage is selected to be less than the predetermined nominal voltage of the lithium-ion cell or battery and greater than the initial charging voltage of the lithium-ion cell or battery when the charging current is held at a constant level equal to the 1.0 C rate for the lithium-ion cell or battery.

16. The charging circuit of claim 15, additionally comprising a smoothing sub-circuit connected between the rectifier sub-circuit and the charge-voltage regulator sub-circuit for smoothing the rectified secondary winding voltage supplied to the charge-voltage regulator sub-circuit.

17. The charging circuit of claim 16, wherein the smoothing sub-circuit is a smoothing capacitor connected between the positive and negative output terminals of the rectifier sub-circuit so that the rectified secondary winding voltage supplied by the rectifier sub-circuit is applied across the smoothing capacitor.

18. The charging circuit of claim 15, wherein the transformer is selected on the basis that the AC line voltage applied to the primary winding thereof is a predetermined maximum AC line voltage.

19. The charging circuit of claim 18, wherein the minimum charging voltage is selected to be approximately equal to the average of (1) the initial charging voltage of the lithium-ion cell or when the charging current is held at a constant level equal to the 1.0 C rate for the lithium-ion cell or battery and (2) the predetermined nominal voltage of the lithium-ion cell or battery.

20. The charging circuit of claim 18 for a single lithium-ion cell, wherein the minimum charging voltage is approximately 3.6 volts.

21. The charging circuit of claim 18, wherein the upper current limit is selected to be not greater than the maximum rate for the lithium-ion cell or battery specified by the manufacturer of the lithium-ion cell or battery.

22. The charging circuit of claim 18, wherein the upper current limit is selected to be not less than the 0.5 C rate nor greater than the 1.0 C rate for the lithium-ion cell or battery.

23. The charging circuit of claim 18, wherein the upper current limit is selected to be approximately the 1.0 C rate for the lithium-ion cell or battery.

24. The charging circuit of claim 18, wherein the connection between the negative output terminal of the rectifier sub-circuit and the negative terminal of the lithium-ion cell or battery to be charged is a direct ohmic connection, and the connection between the positive output terminal of the rectifier sub-circuit and the input terminal of the charge-control IC device is a direct ohmic connection.

25. The charging circuit of claim 16, wherein the transformer is selected on the basis that the AC line voltage applied to the primary winding thereof is a predetermined maximum AC line voltage.

26. The charging circuit of claim 15, wherein the charge voltage regulator sub-circuit comprises a selected suitable charge-control IC device whose input terminal is connected to the positive output terminal of the rectifier sub-circuit, and whose output terminal is connected to the positive terminal of the lithium-ion cell or battery to be charged, and whose ground terminal is connected to the negative terminal of the rectifier sub-circuit and to the negative terminal of the lithium-ion cell or battery to be charged.

27. The charging circuit of claim 26, wherein the charge control IC device is of the low drop-out voltage type.

28. The charging circuit of claim 15, wherein the charge voltage regulator sub-circuit comprises a selected suitable charge-control IC device whose input terminal is connected to the positive output terminal of the rectifier sub-circuit, and whose output terminal is connected to the positive terminal of the lithium-ion cell or battery to be charged, and whose adjustment terminal is connected to one terminal of an adjustable resistor whose other terminal is connected to the negative terminal of the rectifier sub-circuit and to the negative terminal of the lithium-ion cell or battery to be charged, the adjustment terminal also being connected to one terminal of a resistor whose other terminal is connected to the output terminal of the IC device.

29. The charging circuit of claim 28, wherein the charge control IC device is of the low drop-out voltage type.