Dynamic battery charging system and method, and battery charging device

Patent metadata

Field	Value
Publication number	US-12401218-B2
Application number	US-202117904170-A
Country	US
Kind code	B2
Filing date	Feb 11, 2021
Priority date	Feb 14, 2020
Publication date	Aug 26, 2025
Grant date	Aug 26, 2025

Abstract

A dynamic battery charging method for use in a battery charger configured to charge a lead acid battery, including marking a time when battery charger switches from Constant Current (CC) phase to Constant voltage (CV) phase to establish CV Start Time; starting at CV Start Time; calculating Delta Current by subtracting current measurement at particular time interval from previous current measurement at an earlier time interval; terminating CV phase once Delta Current is less than or equal to a particular Delta Current current level OR once the battery charger operating current drops below a particular battery charger operating current; marking CV Finish Time; switching back to another CC phase once CV phase is terminated; and staying at another CC phase for a time period equal to the CV Finish Time minus CV start Time OR until lead acid battery reaches CV voltage plus an additional voltage amount to complete charging.

First claim

The invention claimed is:

1. A dynamic battery charging method for use in a battery charger configured to charge a lead acid battery, the method comprising:
marking a time when the battery charger switches from a Constant Current (CC) phase to a Constant voltage (CV) phase to establish a CV Start Time;
starting at the CV Start Time, begin measuring at successive time intervals an operating current of the battery charger by averaging multiple operating current samples taken during one or more successive time intervals;
calculating a Delta Current by subtracting a current measurement at a particular time interval from a previous current measurement at an earlier time interval;
terminating the CV phase once the Delta Current is less than or equal to a particular Delta Current current level OR once the battery charger operating current drops below a particular battery charger operating current;
marking a CV Finish Time when the battery charger terminates the CV phase;
switching back to another CC phase once the CV phase is terminated; and
staying at the another CC phase for:
a time period equal to the CV Finish Time minus the CV Start Time;
or
a time period from the CV Finish Time until the lead acid battery reaches CV voltage plus a predetermined voltage amount to complete charging of the lead acid battery.

2. The method according to claim 1 , wherein the time interval is a fixed length time interval.

3. The method according to claim 2 , wherein the fixed length time interval can be varied or set to a different fixed length time interval before or during charging operation.

4. The method according to claim 2 , wherein the fixed length time interval is five (5) minutes.

5. The method according to claim 1 , wherein a length of the time interval can vary in a sequence during charging operation.

6. The method according to claim 1 , wherein the multiple operating current samples are taken at fixed lengths of time.

7. The method according to claim 6 , wherein the fixed length of time is one (1) second.

8. The method according to claim 1 , wherein the multiple operating current samples are taken at a timed sequence.

9. The method according to claim 8 , wherein the timed sequence comprises a sequence of fixed time intervals and/or varying time intervals.

10. The method according to claim 1 , wherein the CV phase is terminated once the Delta Current is less than or equal to the particular current level of 40 mA.

11. The method according to claim 10 , wherein the particular battery charger operating current is 1-2 amps.

12. The method according to claim 1 , wherein the CV Time occurs when the value of the operating current meets a CV exit threshold.

13. The method according to claim 1 , wherein instead the CV phase is terminated when a set level of optimization current is met.

14. The method according to claim 13 , wherein a CC optimization current to be used is a value of the operating current when the battery charger exited the CV phase.

15. The method according to claim 1 , wherein the predetermined voltage amount is 500 mV.

16. A battery charger configured to perform a dynamic battery charging method for use in charging a lead acid battery, the method comprising:
marking a time when the battery charger switches from a Constant Current (CC) phase to a Constant voltage (CV) phase to establish a CV Start Time;
starting at the CV Start Time, begin measuring at successive time intervals an operating current of the battery charger by averaging multiple operating current samples taken during one or more successive time intervals;
calculating a Delta Current by subtracting a current measurement at a particular time interval from a previous current measurement at an earlier time interval;
terminating the CV phase once the Delta Current is less than or equal to a particular Delta Current current level OR once the battery charger operating current drops below a particular battery charger operating current;
marking a CV Finish Time when the battery charger terminates the CV phase;
switching back to another CC phase once the CV phase is terminated; and
staying at the another CC phase for:
a time period equal to the CV Finish Time minus the CV Start Time;
or
a time period from the CV Finish Time until the lead acid battery reaches CV voltage plus a predetermined voltage amount to complete charging of the lead acid battery.

17. The battery charger of claim 16 , further comprising a battery charging system using or incorporating the dynamic battery charging method.

Assignees

• Noco Co

Inventors

• Simon Daniel L
• Stanfield James Richard

Classifications

• H02J7/94 Primary

  in response to battery current · CPC title

• H02J7/96 Primary

  in response to battery voltage · CPC title

• G01R31/3842

  combining voltage and current measurements · CPC title

• Y02E60/10

  Energy storage using batteries · CPC title

• H02J7/00714

  Electricity · mapped topic