Battery charging apparatus and method

• US 7,928,698 B2
• Filed: 03/25/2008
• Issued: 04/19/2011
• Est. Priority Date: 03/25/2008
• Status: Active Grant

• Current Assignee: SPX Corporation
• Original Assignee: SPX Corporation
• Inventors: Andelfinger, Richard L.
• Primary Examiner(s): TSO, EDWARD H
• Application Number:
  US12/054,516
• Publication Number:
  US 20090243547A1
• Time in Patent Office: 1,120 Days
• Field of Search: 320/103, 320/107, 320/112, 320/114, 320/128, 320/138, 320/166, 320/167, 307/18, 307/19, 307/21
• US Class Current: 320/138
• CPC Class Codes: H01M 10/06 Lead-acid accumulators semi-lead accumulators H01M10/20
• CPC Class Codes: H01M 10/4264 with capacitors
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A battery charger that includes a primary switching-mode power supply, a secondary switching-mode power supply and a capacitor that is electrically connected to these two power supplies. In operation, this battery charger may be used to reverse the sulfation process in a battery. Also, a battery charging method that may be used to reverse the sulfation process in a battery.

Claims

1. A battery charger, comprising:

a primary switching-mode power supply;

a secondary switching-mode power supply electrically connected to the primary switching-mode power supply;

a capacitor electrically connected to the secondary switching-mode power supply; and

a lead electrically connected to the capacitor and configured to be connected to a battery.

2. The battery charger of claim 1, further comprising:

a control circuit electrically connected to the capacitor, wherein the control circuit connects the capacitor to the battery when both the battery is electrically connected to the lead and the capacitor has been charged to a specified level.

3. The battery charger of claim 2, wherein the control circuit comprises a solid state switch.

4. The battery charger of claim 1, further comprising:

a charging circuit electrically connected to the lead and configured to monitor current travelling to the battery and to detect a charging level in the battery when the battery is electrically connected to the lead.

5. The battery charger of claim 1, further comprising:

a shunt resistor electrically connected to the primary switching-mode power supply.

6. The battery charger of claim 1, further comprising:

a diode electrically connected between the primary switching-mode power supply and the lead.

7. The battery charger of claim 1, wherein the primary switching-mode power supply operates at a lower voltage level and higher current level than the secondary switching-mode power supply.

8. The battery charger of claim 1, wherein the primary switching-mode power supply is configured to operate at a voltage level only slightly higher than a voltage level at which the battery typically operates.

9. The battery charger of claim 1, wherein the secondary switching-mode power supply is configured to operate at a voltage level substantially higher than a voltage level at which the battery typically operates.

10. The battery charger of claim 1, wherein the capacitor comprises a high energy density capacitor.

11. The battery charger of claim 1, wherein at least one of the primary switching-mode power supply and the secondary switching-mode power supply is configured to automatically adjust to operate at an operating voltage level being provided thereto.

12. A method of charging a battery, the method comprising:

partially charging a capacitor using a primary switching-mode power supply electrically connected to the capacitor;

supplementally charging the capacitor using a secondary switching-mode power supply electrically connected to the capacitor; and

discharging a charge from the capacitor into a battery electrically connected to the capacitor once the charge in the capacitor reaches a specified level.

13. The method of claim 12, wherein the supplementally charging step is performed at a lower current level and higher voltage level than the partially charging step.

14. The method of claim 12, further comprising:

periodically repeating the partially charging, supplementally charging and discharging steps over a specified time period.

15. The method of claim 12, wherein the partially charging step comprises charging the capacitor at a voltage level only slightly higher than a voltage level at which the battery typically operates.

16. The method of claim 12, wherein the supplementally charging step comprises charging the capacitor at a voltage level sufficient to reverse sulfation in the battery.

17. The method of claim 12, further comprising:

monitoring a current traveling to the battery;

detecting a charging level in the battery; and

gradually decreasing the current as the charging level in the battery approaches an operating capacity threshold.

18. The method of claim 12, wherein the partially charging and supplementally charging steps comprise choosing the primary switching-mode power supply and the secondary switching-mode power supply to each have power factors above approximately 0.95.

19. The method of claim 12, further comprising:

automatically adjusting at least one of the primary switching-mode power supply and the secondary switching-mode power supply to operate at an operating voltage level being provided thereto.

20. A battery charger, comprising:

primary charging means for partially charging a capacitor, wherein the primary charging means is electrically connected to the capacitor;

supplemental charging means for supplementally charging the capacitor, wherein the supplemental charging means is electrically connected to the capacitor; and

discharging means for discharging a charge from the capacitor into a battery electrically connected to the capacitor once the charge in the capacitor reaches a specified level.