Step-up battery charging management system and control method thereof

• US 9,391,467 B2
• Filed: 01/17/2014
• Issued: 07/12/2016
• Est. Priority Date: 01/22/2013
• Status: Active Grant

• Current Assignee: Silergy Semiconductor Technology (Hangzhou) Ltd. (Silergy Corporation)
• Original Assignee: Silergy Semiconductor Technology (Hangzhou) Ltd. (Silergy Corporation)
• Inventors: Zhao, Chen, Cheng, Shuai, Yao, Jie
• Primary Examiner(s): Do, Thuan
• Application Number:
  US14/158,296
• Publication Number:
  US 20140203763A1
• Time in Patent Office: 907 Days
• Field of Search: 320/107
• US Class Current: 1/1
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process
• CPC Class Codes: H02J 7/00718 in response to charge current gradient
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient

Abstract

In one embodiment, a battery charger can include: (i) a step-up converter configured to generate an output signal by boosting a DC input voltage, where a threshold voltage is greater than the DC input voltage; (ii) a charging control circuit configured to receive the output signal from the step-up converter, and to control charging of a battery; (iii) the charging control circuit being configured to regulate the output signal to maintain a charging current for the battery charging as a trickle current when a battery voltage is less than the threshold voltage; and (iv) the charging control circuit being configured to charge the battery directly by the output signal when the battery voltage is greater than the threshold voltage.

Claims

1. A battery charger, comprising:

a) a step-up converter configured to generate an output signal by boosting a DC input voltage, wherein a threshold voltage is greater than said DC input voltage;

b) a charging control circuit configured to receive said output signal from said step-up converter, and to control charging of a battery;

c) said charging control circuit being configured to regulate said output signal by a power transistor operating in a linear region to maintain a charging current for said battery charging as a trickle current when a battery voltage is less than said threshold voltage, wherein said power transistor is coupled between said step-up converter and said battery; and

d) said charging control circuit being configured to charge said battery directly by said output signal by said power transistor operating in a saturation region when said battery voltage is greater than said threshold voltage.

2. The battery charger of claim 1, wherein said

power transistor

c) comprises a parasitic diode having an anode coupled to said battery, and a cathode coupled to said step-up converter.

3. The battery charger of claim 1, wherein said step-up converter comprises:

a) a power stage circuit having a switching operation controlled by a step-up converter control circuit to maintain said output signal to be substantially constant;

b) said step-up converter control circuit being configured to maintain a voltage of said output signal to be a predetermined operating voltage when said battery voltage is less than said threshold voltage, wherein said predetermined operating voltage is greater than said threshold voltage;

c) said step-up converter control circuit being configured to maintain a current of said output signal to be a predetermined operating current when said battery voltage is greater than said threshold voltage and less than a final voltage; and

d) said step-up converter control circuit being configured to maintain said voltage of said output signal to be said final voltage when said battery voltage equals said final voltage and said battery charging current is not less than a shut-down current threshold, wherein said step-up converter is disabled when said battery charging current is less than said shut-down current threshold.

4. The battery charger of claim 3, wherein said step-up converter control circuit comprises:

a) a first feedback circuit configured to generate a first feedback signal according to an error between said voltage of said output signal and said first operating voltage;

b) a second feedback circuit configured to generate a second feedback signal according to an error between said current of said output signal and said first operating current;

c) a third feedback circuit configured to generate a third feedback signal according to an error between said battery voltage and said final voltage;

d) a selection circuit configured to output a lowest of said first, second, and third feedback signals; and

e) a pulse-width modulation (PWM) control circuit configured to control said switching operation of said power stage circuit according to said output of said selection circuit.

5. The battery charger of claim 4, wherein said first and second feedback circuits are configured to receive a shield signal that selectively increase a value of said first feedback signal or said second feedback signal according to a comparison result of said battery voltage and said threshold voltage.

6. The battery charger of claim 1, further comprising a current-limiting protection circuit configured to limit said battery charging current to limit an input current of said step-up converter when said DC input voltage is less than a current limiting threshold.

7. The battery charger of claim 1, further comprising a short-circuit protection circuit configured to control said battery charging current to be a first current value that is less than said trickle current when said battery voltage is less than a short-circuit protection threshold value.

8. The battery charger of claim 7, wherein said short-circuit protection circuit is configured to control said battery charging current to be a discontinuous current, wherein a maximum value of said battery charging current is greater than a corresponding current when said output signal is said threshold voltage, when an energy-consuming load is connected to said step-up converter, and a load voltage is less than said threshold voltage.

9. The battery charger of claim 1, wherein a topology of said step-up converter comprises at least one of:

Boost, Buck-Boost, Sepic, Cuk, and Zeta.

10. The battery charger of claim 1, further comprising an energy-saving control circuit when a topology of said step-up converter is configured as a synchronous rectifier boost converter, wherein said energy-saving control circuit is configured to control a synchronous switch to be off when said battery charging current is less than an energy-saving mode current threshold value.

11. A method of controlling charging of a battery, the method comprising:

a) boosting, by a step-up converter, a DC input voltage to generate an output signal configured to charge a battery;

b) comparing, by a comparator, a battery voltage against a threshold voltage, wherein said threshold voltage is greater than said DC input voltage;

c) regulating, by a power transistor operating in a linear region, said output signal to maintain a battery charging current to be a trickle current when said battery voltage is less than said threshold voltage, wherein said power transistor is coupled between said step-up converter and said battery; and

d) charging, by said power transistor operating in a saturation region, said battery directly by said output signal when said battery voltage is greater than said threshold voltage.

12. The method of claim 11, wherein

comprises a parasitic diode having an anode coupled to said battery, and a cathode coupled to said step-up converter.

13. The method of claim 11, further comprising:

a) maintaining an output voltage of said step-up converter to be a predetermined operating voltage when said battery voltage is less than said threshold voltage, wherein said predetermined operating voltage is greater than said threshold voltage;

b) maintaining an output current of said step-up converter to be a predetermined operating current when said battery voltage is greater than said threshold voltage and less than a final voltage; and

c) maintaining said output voltage of said step-up converter to be said final voltage when said battery voltage equals said final voltage and said battery charging current is not less than a shut-down current threshold, wherein said step-up converter is disabled when said battery charging current is less than a said shut-down current threshold.

14. The method of claim 13, further comprising:

a) generating a first feedback signal according to an error between a voltage value of said output signal and said predetermined operating voltage;

b) generating a second feedback signal according to an error between a current value of said output signal and said predetermined operating current;

c) generating a third feedback signal according to an error between said battery voltage and said final voltage;

d) controlling the switching operation of said step-up converter according to the lowest one of said first feedback signal, said second feedback signal, and said third feedback signal.

15. The method of claim 14, further comprising selectively increasing a value of said first feedback signal or said second feedback signal according to a comparison result of said battery voltage and said threshold voltage.

16. The method of claim 11, further comprising limiting said battery charging current when said DC input voltage is less than a current limiting threshold value in order to limit an input current of said step-up converter.

17. The method of claim 11, further comprising controlling said battery charging current to be a predetermined current value when said battery voltage is less than a short-circuit protection threshold value, wherein said predetermined current value is less than said trickle current.

18. The method of claim 11, further comprising controlling said battery charging current to be a discontinuous current when an energy-consuming load is coupled to said step-up converter instead of said battery and a load voltage is less than said threshold voltage, wherein a maximum value of said battery charging current is greater than a corresponding current when said output signal is equal to said threshold voltage.

19. The method of claim 11, wherein a topology of said step-up converter comprises at least one of:

Boost, Buck-Boost, Sepic, Cuk, and Zeta.

20. The method of claim 11, further comprising controlling a synchronous switch to be off when said battery charging current is less than an energy-saving mode current threshold value.