Integrated battery charger and system regulator circuit

• US 7,489,109 B1
• Filed: 08/11/2004
• Issued: 02/10/2009
• Est. Priority Date: 06/23/2004
• Status: Expired due to Fees

• Current Assignee: Intersil Americas LLC (Renesas Electronics Corporation)
• Original Assignee: Intersil Americas LLC (Renesas Electronics Corporation)
• Inventors: Henderson, Dean F., Folkes, Donald P., Qian, Jinrong
• Primary Examiner(s): Tso; Edward
• Assistant Examiner(s): BOATENG, ALEXIS ASIEDUA
• Application Number:
  US10/915,800
• Time in Patent Office: 1,644 Days
• Field of Search: 320/135, 320/137, 320/140, 320/161, 320/162, 320/159, 320/134
• US Class Current: 320/135
• CPC Class Codes: H02J 1/102 being switching converters H02J1/108, H02J1/12 take precedence
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/007 Regulation of charging or discharging current or voltage
• CPC Class Codes: H02J 7/04 Regulation of charging current or voltage

Abstract

An integrated regulator and charging system including a DC/DC converter, a P-channel device, a battery system and a system/charger controller. The DC/DC converter converts an input voltage to a regulated voltage on a system bus. The battery system includes a rechargeable battery and a current sense device coupled in series between the drain of the P-channel device and ground, where the source of the P-channel device is coupled to the system bus. The system charger/controller regulates the system bus at a minimum voltage level when the battery voltage is below the minimum voltage level, such as a deeply discharged battery. The system charger/controller also regulates charge current through the battery when its voltage is between the minimum voltage level and a maximum voltage level and regulates the system bus at the maximum voltage level when the battery voltage is at the maximum voltage level.

Claims

1. An integrated battery charger and system regulator, comprising:

a converter having a first terminal coupled to an input node for receiving an input voltage, a second terminal coupled to a system node, and a control terminal for controlling said converter to convert said input voltage to a system voltage on said system node;

a regulator device having a control terminal and first and second terminals forming a controlled current path coupled in a charge path of a rechargeable battery, said first terminal coupled to said system node;

a current sensing device that senses charge current of said charge path; and

a controller, coupled to said current sensing device, said converter control input and said regulator device control terminal, that controls said converter to regulate said system voltage between minimum and maximum voltage levels and that operates in a plurality of modes, including a trickle charging mode for controlling said regulator device to maintain said system node at said minimum voltage level, a current charging mode for regulating said charge current, and a voltage control mode for maintaining said system node at said maximum voltage level.

2. The integrated battery charger and system regulator of claim 1, wherein said regulator device comprises a P-channel field-effect transistor (FET) having a gate as said control terminal, a source as said first terminal and a drain as said second terminal.

3. The integrated battery charger and system regulator of claim 2, wherein said controller operates said FET in a linear mode during said trickle charging mode when said drain of said FET is pulled below said minimum voltage level.

4. The integrated battery charger and system regulator of claim 1, wherein said converter is a synchronous buck converter comprising:

a first N-channel device having a drain coupled to said input voltage, a source coupled to a phase node and a gate coupled to said controller;

a second N-channel device having a drain coupled to said phase node, a source coupled to ground and a gate coupled to said controller; and

an inductor having a first end coupled to said phase node and a second end coupled to said system node.

5. The integrated battery charger and system regulator of claim 4, wherein said controller adjusts a duty cycle of said first N-channel device during said trickle charging mode to regulate said system voltage at said minimum voltage level and during said voltage control mode to regulate said system voltage at said maximum voltage level.

6. The integrated battery charger and system regulator of claim 1, further comprising a battery pack incorporating said regulator device coupled to a plurality of series-coupled battery cells coupled to said current sensing device.

7. The integrated battery charger and system regulator of claim 1, wherein said maximum voltage level is sufficiently low to improve efficiency of a plurality of step-down DC/DC converters coupled to said system node as compared to being coupled to said input voltage.

8. The integrated battery charger and system regulator of claim 1, further comprising:

an adjustable AC adapter that converts an AC voltage to said input voltage based on an adjust signal; and

said converter providing said adjust signal to maintain said input voltage at a predetermined offset above said system voltage.

9. A regulator and charging system, comprising:

a DC/DC converter that converts an input voltage to a regulated voltage on a system bus;

a P-channel device having a source coupled to said system bus, a drain and a gate;

a battery system including a rechargeable battery and a current sense device coupled in series between said drain of said P-channel device and ground; and

a system charger/controller having a first output coupled to said DC/DC converter, a second output coupled to said gate of said P-channel device, a first input coupled to said system bus, a second input coupled to said current sense device, and a third input coupled to said battery;

wherein said system charger/controller regulates said system bus at a minimum voltage level when said third input is pulled below said minimum voltage level, regulates charge current through said battery while said third input is between said minimum voltage level and a maximum voltage level, and regulates said system bus at said maximum voltage level when said third input is at said maximum voltage level.

10. The regulator and charging system of claim 9, wherein said system charger/controller operates said P-channel device in a linear mode when said third input is pulled below said minimum voltage level and turns on said P-channel device when said third input is at or above said minimum voltage level.

11. The regulator and charging system of claim 9, wherein said DC/DC converter comprises:

a first N-channel FET having a drain coupled to said input voltage, a source coupled to a phase node and a gate coupled to said system charger/controller;

a second N-channel FET having a drain coupled to said phase node, a source coupled to ground and a gate coupled to said system charger/controller; and

an inductor having a first end coupled to said phase node and a second end coupled to said system bus.

12. The regulator and charging system of claim 11, wherein said system charger/controller adjusts duty cycle of said first and second N-channel FETs to regulate voltage on said system bus.

13. The regulator and charging system of claim 9, wherein said current sense device comprises a resistor coupled between said second and third inputs of said system charger/controller and wherein said battery is coupled between said third input of said system charger/controller and ground.

14. The regulator and charging system of claim 9, wherein said current sense device comprises a resistor coupled between said second input of said system charger/controller and ground and wherein said battery is coupled between said second and third inputs of said system charger/controller.

15. A method of charging a battery using a system/charger regulator circuit, comprising:

regulating a system bus to a voltage level between a minimum level and a maximum level;

controlling a regulator device, coupled between the system bus and the battery, to maintain the system bus at the minimum level to trickle charge the battery when its voltage is below the minimum level, wherein said trickle charge comprises a constant and reduced charging current;

maintaining constant charge current through the battery when its voltage is between the minimum and maximum levels; and

regulating the system bus at the maximum level when the battery voltage is approximately at the maximum level.

16. The method of claim 15, wherein said regulating the system bus to a voltage level between a minimum level and a maximum level and said regulating the system bus at the maximum level comprises adjusting duty cycle of a DC/DC converter.

17. The method of claim 15, wherein said controlling a regulator device comprises operating the regulator device in a linear mode.

18. The method of claim 15, further comprising turning on the regulator device when the voltage of the battery is at or above the minimum level.

19. The method of claim 15, wherein said maintaining constant charge current through the battery includes sensing current through the battery.

20. The method of claim 15, further comprising monitoring the voltage of the battery.