Ni-Cad battery charger circuit

• US 5,196,780 A
• Filed: 09/10/1991
• Issued: 03/23/1993
• Est. Priority Date: 09/10/1991
• Status: Expired due to Fees

• Current Assignee: David R. Pacholok
• Original Assignee: David R. Pacholok
• Inventors: Pacholok, David R.
• Primary Examiner(s): Stephan, Steven L.
• Assistant Examiner(s): NGUYEN, MATTHEW VAN
• Application Number:
  US07/757,237
• Time in Patent Office: 560 Days
• Field of Search: 320/40, 320/20, 320/21, 320/32, 320/35, 320/36
• US Class Current: 320/148
• CPC Class Codes: H02J 7/00302 Overcharge protection
• CPC Class Codes: H02J 7/00309 Overheat or overtemperature protection
• CPC Class Codes: H02J 7/0047 with monitoring or indicating devices or circuits
• CPC Class Codes: H02J 7/007184 in response to battery voltage gradient
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters

Abstract

An analog, low-cost nickel-cadmium battery charger including a fast charging current circuit and a slow charging current circuit, both of which are controlled by a comparator circuit which compares the characteristic negative change in battery voltage at the onset of overcharge to the stored charging voltage and changes the charging current from fast charging to slow charging when the battery voltage begins to decrease at the onset of overcharge, a timer that shuts off the fast charging current circuit after a predetermined period of time and reverts to the slow charging current circuit, and a thermostat that checks the temperature of the battery and, in the event of overheating or cooling below a predetermined temperature, stops all charging of the battery.

Claims

1. A battery charger having a fast charging current circuit and a slow charging current circuit comprising:

means for coupling the fast charging current circuit to a battery to provide a voltage developed across the battery and to a resistor/capacitor time constant circuit for storing a voltage in the capacitor of the time constant circuit such that the capacitor voltage tries to catch up with the battery voltage;

means for comparing the instantaneous voltage developed across the battery in response to the fast charging current with the instantaneous voltage stored by the capacitor; and

means for removing the fast charging current circuit from, and coupling the slow charging current circuit to, the battery when the voltage stored by the capacitor exceeds the battery voltage developed by the fast charging current.

2. A battery charger as in claim 1 further comprising a timer coupled to the fast charging current circuit and the slow charging current circuit for automatically removing the fast charging current from the battery and coupling the slow charging current to the battery after a predetermined time period.

3. A battery charger as in claim 2 further comprising:

a thermostat coupled to the battery for detecting the temperature of the battery; and

means coupling the thermostat to the fast and slow charging current circuits for removing the fast charging current circuit from and coupling the slow charging current circuit to the battery when the battery reaches a predetermined temperature.

4. A battery charger as in claim 1 wherein the fast charging current circuit supplies a 13 microsecond charging pulse at a rate of 22 KHz to provide a five amp charge.

5. A battery charger as in claim 1 wherein the slow charging circuit provides 50-300 milliamp continuous charge current at the rating of the battery being charged.

6. A battery charger as in claim 1 wherein the battery being charged is a nickel-cadmium battery.

7. A charging circuit for a battery having a charge voltage versus time curve that increases until a relatively flat portion then decreases at the onset of overcharge, the circuit comprising:

a fast charging circuit coupled to the battery;

a series coupled resistance and capacitance for receiving and storing the charging current;

a comparator circuit having first and second inputs;

conductor means coupling the voltage stored by the capacitance to the first comparator input;

resistor means coupling the battery voltage to the second comparator input;

said comparator circuit detecting a decrease in battery voltage at the onset of overcharge of the battery and generating an output signal when the voltage stored by the capacitor is greater than the battery voltage at the onset of overcharge;

a slow charging current circuit; and

electro-optic means coupled to the comparator circuit for receiving the comparator output signal, removing the fast charging current from the battery and coupling the slow charging current to the battery when the battery voltage decrease is detected.

8. A charging circuit as in claim 7 wherein said means for removing the fast charging current circuit from and coupling the slow charging current circuit to the battery comprises:

control means for generating 13 microsecond pulses at 22 KHz to provide a five ampere fast charging current and generating pulses at 1.5 KHz to provide a 50-300 milliamp continuous slow charging current;

an electro-optic circuit coupled to the control means and the comparator circuit such that in a first conducting state of said electro-optic circuit, said control means causes generation of the 13 microsecond pulses at 22 KHz to provide a five amps charging rate for a fast charge and in a second non-conducting state of said electro-optic circuit said control circuit causes generation of the pulses at 1.5 KHz to provide a 50-300 milliamp charging rate for a slow charge; and

means coupling the output of the comparator circuit to the electro-optic circuit to cause the non-conducting state and disconnect the fast charging current circuit from and connect the slow charging current circuit to the battery when the comparator generates the output signal.

9. A charging circuit as in claim 7 further comprising circuit means for causing said capacitor to charge to within 0.6 volts of battery voltage at an increased rate over its normal charging rate when the fast charging current circuit is coupled to a fully-charged battery so as to speed the circuit response to the decrease of the battery voltage at the onset of overcharge and allow fast charge termination in substantially 1.5 minutes.

10. A charging circuit as in claim 9 wherein said capacitor charging means comprises:

a charging resistor coupled in series with the capacitor; and

a first diode coupled in parallel with the series coupled resistor to receive the charging current for the capacitor.

11. A charging circuit as in claim 7 further comprising diode means for causing said capacitor to bypass the charging resistor during discharge so as to increase the capacitor discharge rate thereby allowing successive batteries to be inserted in the charger in succession without the need for waiting for the capacitor to discharge through a long time constant because of the charging resistor.

12. A charging circuit as in claim 11 wherein the diode means for increasing the discharge rate of the capacitor is a second diode coupled in parallel with the charging resistor in opposite polarity to said first diode.

13. A method of charging a battery with a fast charging current circuit and a slow charging current circuit, the method comprising the steps of:

coupling the fast charging current circuit to a battery to provide a voltage developed across the battery and to a resistor/capacitor time constant circuit for storing a voltage in the capacitor of the time constant circuit such that the capacitor voltage tries to catch up with the battery voltage;

comparing the instantaneous battery voltage developed by the fast charging current with the instantaneous capacitor voltage developed by the fast charging current; and

removing the fast charging current circuit from, and coupling the slow charging current circuit to, the battery when the voltage across the capacitor exceeds the battery voltage.

14. A method as in claim 13 further including the steps of:

supplying a 13 microsecond charging current pulse at the rate of 22 KHz to provide a five amp charge as the fast charging current; and

reducing the 22 KHz charging current pulse frequency to 1.5 KHz to provide a 50-300 milliamp continuous charge at the rating of the battery being charged as the slow charging current.

15. A method as in claim 14 further including the step of charging a nickel-cadmium battery with the fast charging and slow charging current.