Method and system for charging multi-cell lithium-based batteries

• US 7,262,580 B2
• Filed: 12/30/2005
• Issued: 08/28/2007
• Est. Priority Date: 11/22/2002
• Status: Expired due to Term

• Current Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Original Assignee: Milwaukee Electric Tool Corporation (Techtronic Industries Company Limited)
• Inventors: Scheucher, Karl F., Johnson, Todd W., Glasgow, Kevin L., Rosenbecker, Jay J., Meyer, Gary D.
• Primary Examiner(s): Tso; Edward H
• Application Number:
  US11/322,782
• Publication Number:
  US 20060108975A1
• Time in Patent Office: 606 Days
• Field of Search: 320/106, 320/110, 320/116, 320/125, 320/132, 320/141, 320/150
• US Class Current: 320/110
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H02J 7/00036 Charger exchanging data with battery
• CPC Class Codes: H02J 7/00038 using passive battery identification means, e.g. resistors or capacitors identification by mechanical connections H02J7/0045
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0014 Circuits for equalisation of charge between batteries
• CPC Class Codes: H02J 7/0019 using switched or multiplexed charge circuits
• CPC Class Codes: H02J 7/00302 Overcharge protection
• CPC Class Codes: H02J 7/00306 Overdischarge protection
• CPC Class Codes: H02J 7/00309 Overheat or overtemperature protection
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H02J 7/0036 using connection detecting circuits H02J7/0034 takes precedence
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/0048 Detection of remaining charge capacity or state of charge [SOC]
• CPC Class Codes: H02J 7/0069 Charging or discharging for charge maintenance, battery initiation or rejuvenation
• 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 7/007182 in response to battery voltage
• CPC Class Codes: H02J 7/007194 of the battery
• CPC Class Codes: H02J 7/04 : Regulation of charging current or voltage
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries

Abstract

A method and system for battery charging. In some aspects, a battery charger including at least one terminal to electrically connect to a lithium-based chemistry battery pack and a controller operable to provide a charging current to the battery pack through the at least one terminal. The controller is operable to select a threshold for a charging function according to a nominal voltage of the battery pack.

Claims

1. A battery charger comprising:

at least one terminal to electrically connect to a lithium-based chemistry battery pack, the battery pack having a nominal voltage and including a plurality of lithium-based battery cells, each battery cell of the plurality of battery cells having an individual state of charge; and

a controller operable to provide pulses of constant charging current to the battery pack though the at least one terminal, wherein the length of the pulses and the time between the pulses are based at least in part on the individual state of charge of at least one battery cell of the battery pack.

2. The battery charger as set forth in claim 1 wherein the nominal voltage of the battery pack is included in the voltage range of approximately 9.6-V to approximately 30-V.

3. The battery charger as set forth in claim 1 wherein the controller includes a first charging module and a second charging module, the first charging module operable to provide a first charging current to the battery pack and the second charging module operable to provide a second charging current to the battery pack.

4. The battery charger as set forth in claim 3 wherein the first charging current and the second charging current differ in one of average current amplitude and duty-cycle.

5. The battery charger as set forth in claim 4 wherein the first charging module includes a fast charge module.

6. The battery charger as set forth in claim 5 wherein the first charging current includes a fast charge current.

7. The battery charger as set forth in claim 3 wherein the controller further includes a third charging module and a fourth charging module, the third charging module operable to provide a third charging current to the battery pack and the fourth charging module operable to provide a fourth charging current.

8. The battery charger as set forth in claim 7 wherein the first charging module is a fast charging module, the second charging module is a step charging module, the third charging module is a trickle charging module, and the fourth charging module is a maintenance charging module.

9. The battery charger as set forth in claim 8 wherein the first charging current is a fast charge current, the second charging current is a step charge current, the third charging current is a trickle charge current, and the fourth charging current is a maintenance charge current.

10. The battery charger as set forth in claim 3 wherein the controller includes a charging algorithm.

11. The battery charger as set forth in claim 10 wherein the controller implements the charging algorithm in the first charging module and in the second charging module.

12. The battery charger as set forth in claim 11 wherein the controller further includes a third charging module and a fourth charging module, the third charging module operable to provide a third charging current to the battery pack and the fourth charging module operable to provide a fourth charging current, the controller implementing the charging algorithm in the third charging module and in the fourth charging module.

13. The battery charger as set forth in claim 12 wherein the first charging module is a fast charging module, the second charging module is a step charging module, the third charging module is a trickle charging module, and the fourth charging module is a maintenance charging module.

24. The battery charger as set forth in claim 11 wherein the controller implements the charging algorithm in a first manner in the first charging module and in a different second manner in the second charging module.

14. A battery charger comprising:

a housing;

at least one terminal to electrically connect to a battery pack supported by the housing, the battery pack including a plurality of lithium-based battery cells, each battery cell of the plurality of battery cells having an individual state of charge; and

a controller operable to supply a charging current to the battery pack through the at least one terminal, the controller being operable to control the charging current being supplied to the battery pack based at least in part on the individual state of charge of at least one battery cell,

wherein the controller is further operable to supply a charging current to the battery pack by supplying the charging current in a plurality of pulses of charging current, the plurality of pulses each having a first period of time, in which the charging current is being supplied to the battery pack at a predefined amplitude, and a second period of time, in which the supply of charging current is suspended.

15. The battery charger as set forth in claim 14 wherein the controller is further operable to control the charging current being supplied to the battery pack by modifying at least one of the first period of time and the second period of time.

16. The battery charger as set forth in claim 15 wherein the controller is operable to modify at least one of the first period of time and the second period of time by shortening the first period of time.

17. The battery charger as set forth in claim 14 and wherein the controller is operable to receive the individual state of charge of each battery cell of the plurality of battery cells.

18. A battery charger comprising:

a housing;

at least one terminal to electrically connect to a battery pack supported by the housing, the battery pack including a plurality of lithium-based battery cells, each battery cell of the plurality of battery cells having an individual state of charge; and

a controller operable to supply a charging current to the battery pack through the at least one terminal, the controller being operable to control the charging current being supplied to the battery pack based at least in part on the individual state of charge of at least one battery cell,

wherein the controller includes a first charging module and a second charging module, the first charging module being operable to provide a first charging current to the battery pack, the second charging module being operable to provide a second charging current to the battery pack, and wherein the controller implements one of the first charging module and the second charging module based at least in part on the individual state of charge of the at least one battery cell.

19. The battery charger as set forth in claim 18 wherein the first charging current and the second charging current differ in one of average current amplitude and duty-cycle.

20. A battery charger comprising:

a housing;

at least one terminal to electrically connect to a battery pack supported by the housing, the battery pack including a plurality of lithium-based battery cells, each battery cell of the plurality of battery cells having an individual state of charge; and

a controller operable to supply a charging current to the battery pack through the at least one terminal, the controller being operable to control the charging current being supplied to the battery pack based at least in part on the individual state of charge of at least one battery cell,

wherein the controller includes a charging algorithm, and wherein the controller is operable to supply a charging current to the battery pack based on the charging algorithm, and

wherein the controller implements the charging algorithm in a first charging module and in a second charging module.

21. The battery charger as set forth in claim 20 and wherein the controller implements the charging algorithm in a first manner in the first charging module and in a second manner in the second charging module, the second manner being different than the first manner.

22. The battery charger as set forth in claim 21 wherein the controller further includes a third charging module and a fourth charging module, the third charging module being operable to provide a third charging current to the battery pack, the fourth charging module being operable to provide a fourth charging current, the controller implementing the charging algorithm in the third charging module and in the fourth charging module.

23. An electrical combination comprising:

a battery having a battery temperature and including

a battery housing,

a plurality of lithium-based battery cells supported by the battery housing, each battery cell having an individual state of charge,

at least one battery terminal supported by the battery housing and electrically connected to the plurality of battery cells, and

a battery controller operable to measure the individual state of charge of each battery cell and to measure the temperature of the battery; and

a battery charger including

a charger housing,

at least one charger terminal to electrically connect to the at least one battery terminal, and

a controller operable to supply a charging current to the battery through the at least one terminal, the controller being operable to control the charging current being supplied to the battery based at least in part on the individual state of charge of at least one battery cell,

wherein the battery controller is further operable to communicate the temperature of the battery and the individual state of charge of each battery cell to the controller of the battery charger,

wherein the battery further includes a second battery terminal electrically connected to the battery controller, and wherein the battery charger further includes a second charger terminal electrically connected to the controller, the battery controller and the controller of the battery charger being operable to communicate over the second battery terminal and the second charger terminal.

25. The electrical combination as set forth in claim 23 wherein the controller of the battery charger is further operable to control the charging current being supplied to the battery based on the temperature of the battery.

26. The electrical combination as set forth in claim 23 wherein the battery cells have a lithium-manganese spinel chemistry.