Battery charger and charging method

• US 6,791,300 B2
• Filed: 01/23/2003
• Issued: 09/14/2004
• Est. Priority Date: 02/28/2002
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: White, Paul S., Trinh, Danh T., Brotto, Daniele C.
• Primary Examiner(s): Tibbits, Pia
• Application Number:
  US10/349,834
• Publication Number:
  US 20030160594A1
• Time in Patent Office: 600 Days
• Field of Search: 320/151, 320/155, 320/156, 320/157, 320/161, 320/DIG.12, 320/125
• US Class Current: 320/151
• CPC Class Codes: H02J 7/0071 with a programmable schedule
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage

Abstract

The charging method includes the steps of charging a battery pack, sensing voltage of the battery pack, calculating voltage change rate, detecting a first inflection point based on the voltage change rate so long as a voltage step is not detected, detecting a second inflection point based on the voltage change rate so long as a voltage step is not detected, and reducing current sent to the battery pack when both first and second inflection points have been detected.

Claims

1. A charging method for charging batteries, the method comprising:

sending power to a battery pack;

sensing voltage of the battery pack;

calculating voltage change rate;

detecting a first inflection point based on the voltage change rate so long as a step in the battery pack voltage is not detected;

detecting a second inflection point based on the voltage change rate so long as a step in the battery pack voltage is not detected; and

reducing power sent to the battery pack when both first and second inflection points have been detected.

2. The method of claim 1, wherein the reducing step comprises reducing current sent to the battery pack.

3. The method of claim 1, wherein the battery pack has at least one cell having a voltage rating.

4. The method of claim 3, wherein the step in the battery pack voltage to be detected is lower than the voltage rating of the at least one cell.

5. The method of claim 3, wherein the step in the battery pack voltage to be detected is less than 50% of the voltage rating of the at least one cell.

6. The method of claim 1, wherein the sending step comprises sending current to the battery pack.

7. The method of claim 1, wherein the sensing step comprises storing voltage values in a memory stack.

8. The method of claim 7, wherein the step in the battery pack voltage is detected by comparing contiguous voltage values within the memory stack.

9. The method of claim 7, wherein the memory stack is initialized if a step in the battery pack voltage is detected.

10. The method of claim 1, wherein the first inflection point is detected by comparing the voltage change rate to a minimum voltage change rate.

11. The method of claim 1, wherein the second inflection point is detected by comparing the voltage change rate to a maximum voltage change rate.

12. The method of claim 1, further comprising an equalization charge step where individual cell voltages in the battery pack are equalized.

13. The method of claim 1, further comprising a maintenance charge step where the voltage of the battery pack is maintained.

14. A charging apparatus for charging batteries, the apparatus comprising:

a current source for providing current to a battery pack; and

a controller connected to the current source for controlling the current source, wherein the controller (a) senses voltage of the battery pack, (b) calculates voltage change rate, (c) detects a first inflection point based on the voltage change rate so long as a step in the battery pack voltage is not detected, (d) detects a second inflection point based on the voltage change rate so long as a step in the battery pack voltage is not detected, and (e) reduces power sent to the battery pack when both first and second inflection points have been detected.

15. The apparatus of claim 14, wherein the battery pack has at least one cell having a voltage rating.

16. The apparatus of claim 15, wherein the step in the battery pack voltage to be detected is lower than the voltage rating of the at least one cell.

17. The apparatus of claim 15, wherein the step in the battery pack voltage to be detected is less than 50% of the voltage rating of the at least one cell.

18. The apparatus of claim 14, further comprising a memory stack connected to the controller for storing sensed voltage values.

19. The apparatus of claim 18, wherein the step in the battery pack voltage is detected by comparing contiguous voltage values within the memory stack.

20. The apparatus of claim 18, wherein the memory stack is initialized if a step in the battery pack voltage is detected.

21. The apparatus of claim 14, wherein the first inflection point is detected by comparing the voltage change rate to a minimum voltage change rate.

22. The apparatus of claim 14, wherein the second inflection point is detected by comparing the voltage change rate to a maximum voltage change rate.

23. The apparatus of claim 14, wherein the controller controls the current source so that an equalization current is sent to the battery pack so that individual cell voltages in the battery pack are equalized.

24. The apparatus of claim 14, wherein the controller controls the current source so that a maintenance current is sent to the battery pack so that the voltage of the battery pack is maintained.