Battery charger operating method and method usable with plural different power supplies

Patent metadata

Field	Value
Publication number	US-10326292-B2
Application number	US-201815963768-A
Country	US
Kind code	B2
Filing date	Apr 26, 2018
Priority date	Mar 12, 2015
Publication date	Jun 18, 2019
Grant date	Jun 18, 2019

Abstract

A method for charging a battery may comprise: setting an initial low charge current level; repetitively interrupting charging in a periodic cycle, and: measuring an open circuit battery voltage when charging is interrupted, determining from the open circuit battery voltage a corresponding predetermined charging current; applying the predetermined charging current; and repeating the periodic cycle. A method may also comprise: setting an initial charge current level, measuring the supply voltage, and decreasing the charge current level if the measured supply voltage is less than a predetermined voltage.

First claim

What is claimed is:

1. A method for charging at least one rechargeable battery connected to a battery charger, the method comprising:
a) determining whether a battery is present;
b) setting an initial charge current level that is substantially lower than a charge current that the battery can accept;
c) repetitively interrupting charging of the battery at a predetermined timing to define a periodic cycle, and for each periodic cycle:
measuring an open circuit voltage of the battery when charging of the battery is interrupted,
determining from the measured open circuit voltage of the battery a corresponding predetermined level of charging current to be applied to the battery; and
applying charging current to the battery at the corresponding predetermined level of charging current; and

d) repeating the periodic cycle of step c) at least until the open circuit voltage of the battery is at a predetermined voltage indicative of the battery being fully charged or until the battery is disconnected from the battery charger.

2. The method of claim 1 further comprising determining a level of current available from an external power supply including:
e) measuring a voltage provided by the external power supply;
f) determining whether the voltage provided by the external power supply is less than a predetermined voltage and, if so:
g) decreasing a current drawn from the external power supply by a predetermined amount; and
h) repeating the foregoing steps of e) measuring, f) determining and g) decreasing until the voltage provided by the external power supply is not less than the predetermined voltage.

3. The method of claim 2 further comprising setting a maximum charge current for the battery that is:
equal to or less than the level of current available from the external power supply; or
equal to or less than the level of current drawn from the external power supply when the voltage provided by the external power supply is not less than the predetermined voltage.

4. The method of claim 1 wherein the initial charge current level is at a level of current that is safe for applying to a battery irrespective of its temperature, or irrespective of its state of charge, or irrespective of its temperature and its state of charge.

5. The method of claim 1 wherein the initial charge current level is substantially zero if a temperature is not within a predetermined range of temperature or if battery voltage is at or above the predetermined voltage indicative of the battery being fully charged.

6. The method of claim 5 wherein thereafter the charge current is set to a predetermined test current level to verify that the battery is in a condition to accept charging in accordance with steps c) and d) of claim 1 .

7. The method of claim 1 wherein the corresponding predetermined level of charging current to be applied to the battery is substantially zero when the measured open circuit voltage of the battery is greater than or equal to a voltage indicative of full charge for the battery.

8. The method of claim 1 further comprising:
reducing the charging current applied to the battery substantially to zero for a period of time after the open circuit voltage of the battery is at a predetermined voltage indicative of the battery being fully charged; or
reducing the charging current applied to the battery substantially to zero for a predetermined period of time after the open circuit voltage of the battery is at a predetermined voltage indicative of the battery being fully charged.

9. The method of claim 8 further comprising:
applying charging current to the battery after the predetermined period of time; or
applying charging current to the battery after the predetermined period of time at least until the open circuit voltage of the battery is at a predetermined voltage indicative of the battery being fully charged, thereby to top off the battery charge.

10. The method of claim 1 with the battery charger in combination with an external source of electrical power, said method further comprising:
receiving electrical power from the external source of electrical power via a first electrical connector.

11. The method of claim 10 further comprising:
employing a second electrical connector for receiving electrical power from a second external source of electrical power, wherein the first electrical connector and the second electrical connector are closely adjacent each other such that an external electrical connector inserted into one of the first electrical connector and the second electrical connector physically interferes with and prevents another external electrical connector from being plugged into the other of the first electrical connector and the second electrical connector.

12. The method of claim 10 wherein said first electrical connector includes a connector guide and wherein an electrical connector configured to mate therewith comprises:
an elongated connector body defining a longitudinal direction and having an electrical cable extending from the elongated connector body;
an electrical connector frame at one end of said elongated connector body;
a longitudinal alignment feature on said elongated connector body configured for aligning said elongated connector body with the connector guide;
a guide feature on said elongated connector body defining a unique orientation of said elongated connector body; and
a retaining feature on said elongated connector body configured for retaining said elongated connector body in the connector guide,
whereby said elongated connector body when inserted into the connector guide is aligned with the connector guide by the longitudinal alignment feature, is in the unique orientation defined by said guide feature and is retained in the connector guide by said retaining feature.

13. A method for charging at least one rechargeable battery connected to a battery charger, the method comprising:
a) determining whether a battery is present;
b) setting an initial charge current level that is substantially lower than a charge current that the battery can accept;
c) determining a level of current available from an external power supply including:
i) measuring a voltage provided by the external power supply;
ii) determining whether the voltage provided by the external power supply is less than a predetermined voltage and, if so:
iii) decreasing a current drawn from the external power supply by a predetermined amount;

d) repeating the foregoing steps of i) measuring, ii) determining and iii) decreasing of step c) until the voltage provided by the external power supply is not less than the predetermined voltage.

14. The method of claim 13 further comprising setting a maximum charge current for the battery that is:
equal to or less than the level of current available from the external power supply; or
equal to or less than the level of current drawn from the external power supply when the voltage provided by the external power supply is not less than the predetermined voltage.

15. The method of claim 13 wherein the initial charge current level is at a level of current that is safe for applying to a battery irrespective of its temperature, or irrespective of its state of charge, or irrespective of its temperature and its state of charge.

16. The method of claim 13 further comprising:
e) repetitively interrupting charging of the battery at a predetermined timing to define a periodic cycle, and for each periodic cycle:
measuring an open circuit voltage of the battery when charging of the battery is interrupted,
determining from the measured open c

Assignees

• Streamlight Inc

Inventors

• Zeisler Jon C
• Sharrah Raymond L
• Ziegenfuss Peter J
• Boris Thomas D

Classifications

• H02J7/975

  in response to temperature · CPC title

• H02J7/963

  in response to battery voltage gradient · CPC title

• H02J7/825

  Detection of fully charged condition · CPC title

• H02J7/751

  concerning the insertion or the connection of the batteries · CPC title

• H02J7/663

  using battery or load disconnect circuits (H02J9/002 takes precedence) · CPC title