Method and apparatus for charging batteries

• US 4,956,597 A
• Filed: 02/28/1989
• Issued: 09/11/1990
• Est. Priority Date: 02/04/1987
• Status: Expired due to Fees

• Current Assignee: Japlar Monarch Company
• Original Assignee: American Monarch Corporation
• Inventors: Engleman, Rudolph, Heavey, Frederick D.
• Primary Examiner(s): HICKEY, ROBERT
• Application Number:
  US07/317,102
• Time in Patent Office: 560 Days
• Field of Search: 320/14, 320/21, 320/22, 320/39
• US Class Current: 320/129
• CPC Class Codes: H02J 7/00711 with introduction of pulses during the charging process

Abstract

A method and apparatus for charging batteries of the type characterized by entry into a gassing phase just prior to reaching full charge, are disclosed. Means are provided for periodically applying a load across the battery terminals during charging of the battery and for accurately measuring the battery discharge through the load. All signals other than those directly attributable to the battery energization of the load are removed from the measured signal. The isolated load response signal is compared to a predetermined threshold value established for the battery being charged to accurately determine when the battery enters into its gassing phase. Battery charging is maintained following entry of the battery into its gassing phase for a period of time known to return a predetermined overcharge of approximately 5 to 15% to the battery.

Claims

1. Apparatus for charging a battery of the type that enters into a gassing phase when full charge is approached, comprising:

(a) means for applying charging current to charging terminals of the battery;

(b) means operatively connected with said battery charging terminals for periodically operatively connecting a load across said battery terminals;

(c) means operatively connected to said load for sensing the electrical response of said load when energized by said battery and for providing a sensed load signal in response thereto;

(d) means operatively connected to receive said sensed load signal for isolating therefrom that portion of said sensed load signal attributable only to energization of said load by said battery;

(e) means operatively connected to receive said isolated sensed load signal for determining therefrom when said battery enters its gassing phase and for producing a gassing phase signal indicative of the gassing phase condition of said battery; and

(f) means operatively connected with said battery and to receive said gassing phase signal for applying a predetermined overcharge to said battery after said battery has entered into its gassing phase.

2. Battery charging apparatus as recited in claim 1, wherein said means for periodically applying a load to said battery terminals operates on a load applying duty cycle of less than about 1%.

3. Battery charging apparatus as recited in claim 1, wherein said sensing means measures the absolute value of said electrical response of said load.

4. Battery charging apparatus as recited in claim 3, wherein said sensing means includes a linear amplifier operatively connected for amplifying, without saturation, said absolute value signal and for producing said sensed load signal therefrom.

5. Battery charging apparatus as recited in claim 1, wherein said isolating means includes means for filtering out from said sensed load signal, noise signals and charging voltage signals caused by said charging current supply means.

6. Battery charging apparatus as recited in claim 1, wherein said overcharge means includes means for returning an overcharge to said battery in the range of from about 5 to 15%.

7. Battery charging apparatus as recited in claim 6, wherein said overcharge means includes means for returning an overcharge to said battery in the range of from about 7 to 12%.

8. Battery charging apparatus as recited in claim 1, further including means for terminating further charging of said battery when said predetermined overcharge has been supplied to the battery.

9. Battery charging apparatus as recited in claim 1, wherein said means for applying a predetermined overcharge to said battery includes first timing means for charging said battery during only a predetermined time interval after said battery has entered into its gassing phase.

10. Battery charging apparatus as recited in claim 1, further including means operatively connected with said battery terminals for sensing the voltage at said battery terminals during charging thereof and for disabling said load connecting means until the voltage at said battery terminals has attained a first predetermined battery voltage known to precede that terminal voltage at which said battery normally enters into its gassing phase.

11. Battery charging apparatus as recited in claim 10, wherein said terminal voltage sensing means is operatively connected to receive said gassing phase signal and further includes second timing means for enabling operation of said load connecting means during only a fixed predetermined time interval after said battery terminal voltage has attained said first predetermined battery voltage and when the state of said gassing phase signal indicates that the battery has entered into its gassing phase.

12. Circuit apparatus for electrically determining entry of a battery being charged, into its gassing region, comprising:

(a) means suitable for connection to the terminals of a battery for periodically operatively applying a load across the battery terminals during charging thereof, whereby a current flow path is established from said battery terminals and through said load;

(b) sensor means operatively connected to said battery for producing a sensed signal responsive to current flow through said battery;

(c) means operatively connected to receive said sensed signal for isolating therefrom that portion of said sensed signal attributable only to the current flow through said battery that is caused by said load and for producing an isolated sensed signal in response thereto;

(d) means for establishing a threshold reference voltage; and

(e) means operatively connected to receive said isolated sensed signal and said threshold reference voltage for comparing said isolated sensed signal with said threshold reference voltage, and for producing a comparison signal in response thereto, wherein said comparison signal is indicative of whether said battery has entered into its gassing phase.

13. Circuit apparatus as recited in claim 12, wherein said means for periodically applying a load across said battery terminals operates on a load applying duty cycle of less than 1%.

14. Circuit apparatus as recited in claim 12, wherein said load is a resistive load, and wherein said sensor means is operative to sense the voltage change across said battery.

15. Circuit apparatus as recited in claim 14, wherein said sensor means measures the absolute value of said voltage change across said battery.

16. Circuit apparatus as recited in claim 15, wherein said sensor means includes a linear amplifier operatively connected for amplifying in its linear range, said absolute value signal and for producing said sensed signal therefrom.

17. Circuit apparatus as recited in claim 12, wherein said isolating means includes means for filtering out from said sensed signal, noise signals and signals introduced to said sensed signal resulting from charging of the battery.

18. Circuit apparatus as recited in claim 12, wherein said threshold reference voltage is set at a value such that the magnitude of said sensed signal must change by a factor of about 2 to 5 times within relatively few loading cycles of said battery, before said comparison signal indicates entry of said battery into its gassing phase.

19. A method of charging a battery of the type that enters into a gassing phase as full charge of the battery is approached, comprising the steps of:

(a) applying a charging current to the terminals of the battery;

(b) periodically operatively applying an electrical load to the battery;

(c) obtaining a responsive signal from the load when it is operatively connected to the battery;

(d) isolating from said load responsive signal that portion thereof attributable only to energization of said load by said battery;

(e) determining entry of the battery into its gassing phase from said isolated load responsive signal; and

(f) applying a predetermined overcharge to said battery after said battery enters its said gassing phase.

20. A method as recited in claim 19, wherein the step of periodically applying an electrical load to the battery is performed on a load applying duty cycle of less than about 1%.

21. The method as recited in claim 19, wherein the step of obtaining a responsive signal from the load includes measuring the absolute value of the electrical response of said load to energization by said battery.

22. A method as recited in claim 19, wherein the step of applying a predetermined overcharge to said battery includes application of a predetermined overcharge to said battery in the range of from about 5 to 15%.

23. A method as recited in claim 19, wherein the step of applying a predetermined overcharge to said battery includes application of a predetermined overcharge to said battery in the range of from about 7 to 12%.

24. A method as recited in claim 19, including the steps of predicting a charging voltage that will occur at the battery terminals at a time in the charging operation of said battery just prior to entry of said battery into its gassing phase, and disabling said periodic application of said load to the battery during charging of the battery until said predicted charging voltage occurs at the battery terminals.

25. The method as recited in claim 19, wherein the step of determining entry of the battery into its gassing phase includes comparing said load responsive signal with a predetermined threshold signal and providing a gassing phase confirmation signal when said load responsive signal corresponds to said threshold signal.

26. The method as recited in claim 25, including the step of disabling application of charging current to the terminals of the battery and application of said electrical load to the battery if said load responsive signal does not correspond to said threshold signal within a predetermined time interval following initiation of the comparison process.

27. The method as recited in claim 19, wherein the step of applying a predetermined overcharge to said battery comprises maintaining said charging current application to the terminals of said battery for a predetermined time interval after said determination has been made that said battery has entered into its said gassing phase.

28. A method of determining entry of a battery being charged, into its gassing phase, comprising the steps of:

(a) applying a resistive load across the battery terminals at periodic predetermined intervals of time during the charging cycle, the length of said intervals being less than about 10% of the anticipated time required to maximize overcharge of the battery during its gassing phase;

(b) monitoring the voltage level caused at the resistive load;

(c) isolating the battery component of the monitored voltage level signal from other signal components which comprise said monitored voltage level;

(d) comparing said isolated load signal with a predetermined threshold value signal; and

(e) determining entry of said battery into its gassing phase based on said comparison.

29. The method as recited in claim 28, wherein the length of said intervals at which said resistive load is applied across the battery terminals is less than about 5% of the anticipated time required to maximize overcharge of the battery during its gassing phase.

30. The method as recited in claim 28, wherein said resistive load is applied across the battery terminals on a duty cycle of less than about 1%.

31. The method as recited in claim 28, wherein the step of monitoring the voltage level at the resistive load includes measuring the absolute value of the voltage drop across said load.