Fast charger for high capacity batteries
First Claim
1. A fast charger for high capacity batteries, comprising:
- an input power conditioner including an AC input rectifier yielding rectified input, and a film capacitor coupled with the AC input rectifier, wherein the film capacitor operates at frequency above about 2 kilohertz;
a power converter including a buck regulator coupled with the input power conditioner to receive rectified input therefrom, and including switching componentry operating at frequency above about 2 kilohertz, producing a power output; and
an inductive filter coupled in power output-receiving relationship to said power converter, to produce a filtered fast charging power output.
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Abstract
A highly efficient fast charger for high capacity batteries and methods for fast charging high capacity batteries. The fast charger preferably comprises a rectified AC input of single or preferably three phases, with an optional power factor corrected input, minimally filtered with high frequency, high ripple current capacitors, which is switched with a power switching circuit in the “buck” configuration into an inductor/capacitor output filter. Metallized film capacitors are employed, to minimize the rectified 360 Hertz AC component filtering while providing transient switch protection and ripple current requirements for the buck regulator, to provide a high current fast charger with substantially improved power factor. High power, high frequency switching with minimized output filter size provides a highly filtered DC output. The fast charger is adapted to be constructed in a modular design for simple maintenance.
91 Citations
100 Claims
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1. A fast charger for high capacity batteries, comprising:
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an input power conditioner including an AC input rectifier yielding rectified input, and a film capacitor coupled with the AC input rectifier, wherein the film capacitor operates at frequency above about 2 kilohertz;
a power converter including a buck regulator coupled with the input power conditioner to receive rectified input therefrom, and including switching componentry operating at frequency above about 2 kilohertz, producing a power output; and
an inductive filter coupled in power output-receiving relationship to said power converter, to produce a filtered fast charging power output. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 39, 40, 41, 42, 49, 50, 96, 97)
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38. A fast battery charger comprising an AC input rectification conditioner and film capacitor operating above 2 kilohertz, operatively coupled with a buck regulator switching at above 2 kilohertz and inductive filter for producing a filtered fast charaing output, a battery charging power transmission member arranged for transmitting said filtered fast charaing output to a battery, and a programmable controller programmably arranged to control time-varying charging at a fixed charging variable condition, wherein said charging variable is selected from the group consisting of charging voltage and charging current, and wherein said programmable controller is programmably arranged to control time-varying charging according to an IVI charging profile.
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43. A fast battery charger comprising power management circuitry for producing battery charging power, including an AC input rectification conditioner and film capacitor operating above 2 kilohertz, operatively coupled with a buck regulator switching at above 2 kilohertz and inductive filter for producing a filtered fast charging output, a battery charging power transmission member arranged for transmitting said filtered fast charging output to a battery, and a housing having disposed therein said power management circuitry for producing battery charging power, said housing including an openable/closable member for selective access to an interior region of said housing, wherein said openable/closeable member is coupled with a member for producing an open circuit condition in said power management circuitry when said openable/closeable member is opened.
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44. A method of fast charging high capacity batteries, comprising:
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conditioning input power by AC input rectification thereof yielding rectified input, in a circuit including a film capacitor coupled with an AC input rectifier, wherein the film capacitor operates at frequency above about 2 kilohertz;
converting power from said conditioning step in a circuit including a buck regulator and switching componentry operating at frequency above about 2 kilohertz, to produce a power output; and
inductively filtering the power output, to produce a filtered fast charging power output.
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45. A method of charging a a high capacity battery, comprising:
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charging said battery at a rate of greater than 30 Amper per 100 Ampere-hours of battery capacity, to bring the state of charge of said battery from 30% to 80% of full charge in less than about 1.5 hours;
maintaining temperature of said battery below 125°
F. during said charging and transmitting charging energy to said battery during said charging according to an IVI charging profile.- View Dependent Claims (46)
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47. A method of recharging a high capacity battery having a depleted state of charge, comprising:
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charging said battery at a rate of greater than 30 Amperes per 100 Ampere-hours of battery capacity, to bring the state of charge of said battery from 30% to 80% of full charge in less than about 1.5 hours; and
maintaining temperature of said battery below 125°
F. during said charging.- View Dependent Claims (48)
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51. A fast charger for high capacity batteries, comprising:
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(a) an AC input;
(b) means for rectifying AC power from said AC input to produce a rectified output;
(c) means for converting said rectified output to a converted DC output for charging a high capacity battery, said means comprising high frequency, high ripple current capacitors switched with a power switching circuit in a buck configuration into an inductor/capacitor output filter; and
(d) cabling for transmission of the rectified output to the high capacity battery, wherein said means (b) and (c) are arranged for charging the high capacity battery at a charging rate greater than 30 A per 100 Ahrs of capacity to bring the state of charge of the battery from 30% to 80% of full charge in less than 1.5 hrs while maintaining temperature of said battery below 125°
during said charging.- View Dependent Claims (52, 53, 54)
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55. A fast charger for high capacity batteries, comprising:
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(a) an AC in put;
(b) means for rectifying AC power from said AC input to produce a rectified output;
(c) means for converting said rectified output to a converted DC output for charging a high capacity battery, said means comprising high frequency, high ripple current capacitors switched with a power switching circuit in a buck configuration into an inductor/capacitor output filter, and (d) cabling for transmission of the rectified output to the high capacity battery;
wherein said means (c) comprise a first electronic switch driven by a pulse width modulation circuit and a second electronic switch providing a current path when the first switch is off in a pulse width modulation cycle of the first switch. - View Dependent Claims (56, 57, 58)
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59. A method of fast charging a high capacity battery, comprising generating output charging power with rectification and pulse width modulation of an AC input, modulating the output charging power in response to the rectified AC input waveform, and synchronously varying the pulse width modulation duty cycle in proportion and response to the AC ripple voltage of the rectified AC input waveform, to provide a substantially constant DC voltage output charging power, wherein said AC input after said rectification is conditioned in a conditioning circuit including a film capacitor operating at above 2 kilohertz, and converted to said substantially constant DC voltage output charging power by subjecting she conditioned AC input to flower conversion effecting said pulse width modulation, and inductive filtering, wherein said power conversion is effected in a power converter including a buck converter and switching componentry operating at frequency above 2 kilohertz.
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60. A fast battery charger comprising an AC input rectification conditioner and film capacitor operating above 2 kilohertz, operatively coupled with a buck regulator switching at above 2 kilohertz and inductive filter for producing a filtered fast charging output, a battery charging power transmission member arranged for transmitting said filtered fast charging output to a battery, and a programmable controller programmably arranged to control time-varying charging at a fixed charging variable condition, wherein said charging variable is selected from the group consisting of charging voltage and charging current, and wherein said programmable controller is programmably arranged to control time-varying charging according to a predetermined charging profile.
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61. A fast charger for a high capacity battery, comprising:
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an input section including a transformer for voltage adjustment of inputted AC voltage and a rectifier for producing a rectified bus voltage;
a conditioning section arranged to receive the rectified bus voltage, including a first electronic switch, a pulse width modulation circuit driving said first electronic switch, and a second electronic switch providing a current path with the first electronic switch is off in a pulse width modulation cycle of said pulse width modulation circuit, and at least one film capacitor filtering the first electronic switch and output filter circuitry while minimally filtering the bus voltage, said conditioning section producing a conditioned power output; and
an output filter comprising said output filter circuitry, arranged to receive the conditioned power output and produce a charging power output. - View Dependent Claims (62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 98, 99, 100)
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78. A method of fast charging of a high capacity battery, comprising:
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rectifying an input AC voltage to produce a rectified bus voltage;
conditioning the rectified bus voltage, by conditioning circuitry including a first electronic switch, a pulse width modulation circuit driving said first electronic switch, and a second electronic switch providing a current path with the first electronic switch is off in a pulse width modulation cycle of said pulse width modulation circuit, and at least one film capacitor filtering the first electronic switch and output filter circuitry while minimally filtering the bus voltage, to produce a conditioned power output; and
filtering said conditioned power output to produce a charging power output for fast charging of the high capacity battery. - View Dependent Claims (79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95)
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Specification