Battery charging device, battery charging system and method for charging a deeply discharged battery

Abstract

To provide a battery charger (for example, a smart battery charger) for charging a deeply discharged battery, and to provide a battery charge system for charging the deeply discharged battery and a method therefor.SOLUTION: A method of charging a deeply discharged battery using a battery charger comprises the steps of: measuring an output voltage of the deeply discharged battery using the battery charger; and charging the deeply discharged battery in a forcing mode using the battery charger, when the output voltage is a voltage equal to or near 0 volt.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a battery charging device (eg, a smart battery charger) and a battery charging system for charging a deeply discharged battery, and to a battery charging system and method for charging a deeply discharged battery. [Background technology]

[0002] Smart battery chargers implement various protection features to ensure proper use. One commonly implemented protection feature is measuring the battery voltage before the start of a charging cycle. If the battery voltage is too low, the smart battery charger will not start charging. JP 07-298504 A discloses a method for charging a secondary battery, including pulse charging the secondary battery when the voltage of the secondary battery is equal to or lower than a set value, and normally charging the secondary battery when a voltage is detected. JP 2008-300038 A discloses a battery pack that is fully charged when no shock is applied, and is charged at a limited low charge capacity when the battery pack is subjected to a shock. JP 2010-154646 discloses a charge control device that controls charging of a battery that is a power source for a vehicle. JP 2013-219984 A discloses a battery control device configured to detect an internal short circuit of a cell and prevent overcharging of the battery.

[0003] A typical lead-acid battery, under normal use, will not drop to a voltage level low enough to prevent a smart charger from charging it. However, if a current load is applied to the battery and it is left plugged in, the battery voltage can reach nearly 0 V. Under these conditions, a typical smart battery charger will not initiate a charge cycle.

[0004] A smart charger uses a battery pack containing lithium-ion cells and a battery management system (BMS) configured to disconnect the lithium-ion cells from the external battery terminals in case of an error. When the lithium-ion battery is internally disconnected, a voltage of 0V is measured at the external battery terminals. In some BMS implementations, after an over-discharge condition, the external battery voltage remains at 0V even after the error condition is cleared. To recover the battery, an external voltage must be applied. However, in a typical smart battery charger, if the battery voltage is detected as 0V, the charge cycle is not initiated and therefore no charging voltage is applied by the charger.

[0005] Therefore, what is needed is a smart charger, system, and method that allows the smart charger to charge deeply discharged batteries without completely eliminating low voltage protection features. Summary of the Invention [Means for solving the problem]

[0006] The battery charging device (e.g., smart battery charger) according to the present invention can be, for example, a portable automatic battery charger for use with lead acid batteries (e.g., wet, gel, MF, EFB, AGM batteries) and / or lithium ion batteries, both 12V and 24V. The smart battery charging device is configured and designed to charge, for example, automobiles, boats, RVs, SUVs, diesel trucks, motorcycles, ATVs, snowmobiles, personal watercraft, lawnmowers, and other vehicles or equipment. It can also be used as a battery maintenance device, for example, to keep both starter batteries and deep cycle batteries fully charged. It can also monitor battery operation, for example, to charge safely and efficiently without overcharging. The smart battery charging device can also include a built-in battery desulfator, for example, to revive degraded batteries.

[0007] The present invention includes a battery charging device (e.g., a smart battery charger) that includes or is configured with a special charging mode or feature designated as "Force Mode" (e.g., trademark FORCE MODE) that allows the battery charging device to begin charging a deeply discharged battery even if the deeply discharged battery voltage is near 0V (i.e., 0 volts). This allows the battery charging device to be used to charge a deeply discharged lead acid battery or to recover a deeply discharged lithium battery with an open BMS. For example, the battery charging device can be configured to automatically initiate the force mode, or a user can forcefully initiate the force mode of the battery charging device (e.g., by pressing a force mode button).

[0008] The force mode feature allows the battery charger to enter battery charging mode when the battery voltage of a deeply discharged battery (e.g., a deeply discharged vehicle battery) falls below a minimum threshold, for example, to allow the battery charger to charge a deeply discharged lead acid battery and to reset the battery management system (BMS) of a deeply discharged lithium ion battery in the battery charger.

[0009] Force mode operates similarly to normal charging mode, except that for safety reasons it is limited to a short period of time. The timeout period for Force mode may be, for example, 5 minutes, or may be longer or shorter depending on the particular application and the type and size of the deeply discharged battery being charged.

[0010] After the forced mode ends due to a specified forced mode timeout, the battery charger checks the battery voltage. If the battery voltage is above the normal start-up voltage threshold, the battery charger begins charging in its normal mode. If the battery voltage is still too low, the battery charger returns to standby or off mode.

[0011] In forced mode, the device operates without the usual check for low battery voltage, so this mode must be explicitly selected from the user interface, and when this mode is set, feedback is provided to the user from the user interface.

[0012] According to one aspect of the present invention, a battery charging apparatus is provided for jump-starting a deeply discharged vehicle battery, the battery charging apparatus including an internal power source, an optional output port having a positive output and a negative output, a vehicle battery isolation sensor configured to detect the presence or absence of a vehicle battery connected between the positive output and the negative output and in circuit with the positive output and the negative output, a reverse polarity sensor connected in circuit with the positive output and the negative output and configured to detect the polarity of a vehicle battery connected between the positive output and the negative output, a power FET switch connected between the internal power source and the output port, and a microcontroller configured to receive input signals from the vehicle isolation sensor and the reverse polarity sensor, and to provide an output signal to the power FET switch to turn on the power FET switch to connect the internal power source to the output port in response to a signal from the sensor indicating the presence of a vehicle battery at the output port and a signal from the sensor indicating that the positive and negative terminals of the vehicle battery are connected with the proper polarity, respectively.

[0013] According to another aspect of the invention, the internal power source is a rechargeable lithium ion battery pack.

[0014] According to yet another aspect of the present invention, there is provided a charging cable device or jumper cable device comprising: a plug configured to be plugged into an output port of a handheld battery charger jump starter device having an internal power source; and a pair of cables having one end integral with the plug and the other end configured to be separately connected to terminals of a battery.

[0015] The subject matter described herein relates to a method for charging a deeply discharged battery, the method including or consisting of measuring an output voltage of the deeply discharged battery, and charging the deeply discharged battery in a forced mode if the output voltage is at or near 0 volts.

[0016] The subject matter described herein relates to a method for charging a deeply discharged battery, the method including or consisting of: measuring an output voltage of the deeply discharged battery; and if the output voltage is at or near 0 volts, charging the deeply discharged battery in a forced mode, wherein the deeply discharged battery is charged in the forced mode for a predetermined amount of time.

[0017] The subject matter described herein relates to a method for charging a deeply discharged battery, the method including or consisting of: measuring an output voltage of the deeply discharged battery; and if the output voltage is at or near 0 volts, charging the deeply discharged battery in a forced mode, wherein the deeply discharged battery is charged in the forced mode for a predetermined amount of time, the predetermined amount of time being 5 minutes.

[0018] The subject matter described herein relates to a method of charging a deeply discharged battery, the method including or consisting of: measuring an output voltage of the deeply discharged battery; and if the output voltage is at or near 0 volts, charging the deeply discharged battery in a forced mode, the deeply discharged battery being charged in a forced mode for a predetermined amount of time, and the charging of the deeply discharged battery in the forced mode being terminated when the predetermined amount of time is reached.

[0019] The subject matter described herein relates to a method of charging a deeply discharged battery, the method including or consisting of: measuring an output voltage of the deeply discharged battery; and if the output voltage is at or near 0 volts, charging the deeply discharged battery in a forced mode, the deeply discharged battery being charged in a forced mode for a predetermined amount of time, the charging of the deeply discharged battery in the forced mode being terminated when the predetermined amount of time is reached, the method further including measuring the deeply discharged battery after the forced mode is terminated.

[0020] The subject matter described herein relates to a method for charging a deeply discharged battery, the method including or consisting of: measuring an output voltage of the deeply discharged battery; and if the output voltage is at or near 0 volts, charging the deeply discharged battery in a forced mode, the deeply discharged battery being charged in the forced mode for a predetermined amount of time, the charging of the deeply discharged battery in the forced mode being terminated when the predetermined amount of time is reached, the method further including measuring the deeply discharged battery after the forced mode is terminated, and if the deeply discharged battery exceeds a normal start-up voltage threshold after the forced mode is terminated and the deeply discharged battery output voltage is measured, the rechargeable battery charger begins charging in a normal mode.

[0021] The subject matter described herein relates to a method for charging a deeply discharged battery, the method including or consisting of: measuring an output voltage of the deeply discharged battery; and charging the deeply discharged battery in a forced mode if the output voltage is at or near 0 volts; the deeply discharged battery is charged in a forced mode for a predetermined amount of time; the charging of the deeply discharged battery in the forced mode is terminated when the predetermined amount of time is reached; the method further includes measuring the deeply discharged battery after the forced mode is terminated; if the deeply discharged battery is above a normal start-up voltage threshold after the forced mode is terminated and the deeply discharged battery output voltage is measured, the rechargeable battery charger starts charging in a normal mode; if the deeply discharged battery voltage is too low after the forced mode is terminated and the deeply discharged battery output voltage is measured, the rechargeable battery charger returns to a standby mode or an off mode.

[0022] The subject matter described herein relates to a method for charging a deeply discharged battery, the method including or consisting of measuring an output voltage of the deeply discharged battery, and if the output voltage is at or near 0 volts, charging the deeply discharged battery in a forced mode, the deeply discharged battery being a lead acid battery.

[0023] The subject matter described herein relates to a method for charging a deeply discharged battery, the method including or consisting of measuring an output voltage of the deeply discharged battery, and charging the deeply discharged battery in a forced mode if the output voltage is at or near 0 volts, the deeply discharged battery being an over-discharged lithium ion battery having an open battery management system (BMS).

[0024] The subject matter described herein relates to a rechargeable battery charging apparatus for charging a deeply discharged battery, the apparatus comprising or consisting of: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging apparatus, the MCI structured and configured to control operation of the rechargeable battery charging apparatus; a user interface connected to the MCI, the user interface structured and configured to display one or more functions or modes of the rechargeable battery charging apparatus; and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts.

[0025] The subject matter described herein relates to a rechargeable battery charging apparatus for charging a deeply discharged battery, the apparatus comprising or consisting of: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging apparatus, the MCI structured and configured to control operation of the rechargeable battery charging apparatus; a user interface connected to the MCI, the user interface structured and configured to display one or more functions or modes of the rechargeable battery charging apparatus; and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the force mode being configured to operate for a predetermined period of time.

[0026] The subject matter described herein relates to a rechargeable battery charging device for charging a deeply discharged battery, the device comprising or consisting of: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging device, the MCI structured and configured to control operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface structured and configured to display one or more functions or modes of the rechargeable battery charging device; and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the force mode configured to operate for a predetermined period of time, the predetermined period being 5 minutes.

[0027] The subject matter described herein relates to a rechargeable battery charging apparatus for charging a deeply discharged battery, the apparatus comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; and a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging apparatus, the MCI being structured and configured to control the operation of the rechargeable battery charging apparatus. a user interface connected to the MCI, the user interface structured and configured to display one or more functions or modes of the rechargeable battery charging device; and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the force mode being configured to operate for a predetermined period of time, and after the force mode is terminated upon expiration of the predetermined period of time, the rechargeable battery charging device measures the voltage of the deeply discharged battery.

[0028] The subject matter described herein relates to a rechargeable battery charging apparatus for charging a deeply discharged battery, the apparatus comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging apparatus, the MCI being structured and configured to control the operation of the rechargeable battery charging apparatus; and a user interface connected to the MCI, the user interface being configured to control the operation of the rechargeable battery charging apparatus. The rechargeable battery charging device comprises or consists of a user interface structured and configured to display one or more functions or modes of the rechargeable battery charging device, and a controller structured and configured to control charging of the deeply discharged battery, the controller having a forced mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the forced mode being configured to operate for a predetermined period of time, and after the forced mode is terminated upon expiration of the predetermined period, the rechargeable battery charging device measures the voltage of the deeply discharged battery, and if the deeply discharged battery exceeds a normal start-up voltage threshold, the rechargeable battery charging device starts charging in normal mode.

[0029] The subject matter described herein relates to a rechargeable battery charging apparatus for charging a deeply discharged battery, the apparatus comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging apparatus, the MCI being structured and configured to control the operation of the rechargeable battery charging apparatus; and a user interface connected to the MCI. and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the force mode being configured to operate for a predetermined period of time, and after the force mode is terminated upon expiration of the predetermined period of time, the rechargeable battery charging device measures the voltage of the deeply discharged battery, and if the deeply discharged battery voltage is too low, the rechargeable battery charging device returns to a standby mode or an off mode.

[0030] The subject matter described herein relates to a rechargeable battery charging device for charging a deeply discharged battery, the device comprising or consisting of a rechargeable battery having a positive terminal and a negative terminal, a positive battery cable connected or connectable to the positive terminal of the rechargeable battery, a negative battery cable connected or connectable to the negative terminal of the rechargeable battery, a detector for measuring an output voltage of the deeply discharged battery, a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging device, the MCI structured and configured to control operation of the rechargeable battery charging device, a user interface connected to the MCI, the user interface structured and configured to display one or more functions or modes of the rechargeable battery charging device, and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the user interface structured and configured to allow a user to select the force mode.

[0031] The subject matter described herein relates to a rechargeable battery charging apparatus for charging a deeply discharged battery, the apparatus comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging apparatus, the MCI being structured and configured to control the operation of the rechargeable battery charging apparatus; a user interface connected to I, the user interface structured and configured to display one or more functions or modes of the rechargeable battery charging device, and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the user interface structured and configured to allow a user to select the force mode, and the user interface configured to provide user feedback when the rechargeable battery charging device is in the force mode.

[0032] The subject matter described herein relates to a rechargeable battery charging apparatus for charging a deeply discharged battery, the apparatus comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging apparatus, the MCI being structured and configured to control the operation of the rechargeable battery charging apparatus; and a user interface connected to the MCI. and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the user interface structured and configured to allow a user to select the force mode, the user interface configured to provide user feedback when the rechargeable battery charging device is in the force mode, the user feedback being provided by lighting a light emitting diode (LED).

[0033] The subject matter described herein relates to a rechargeable battery charging apparatus for charging a deeply discharged battery, the apparatus comprising or consisting of: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging apparatus, the MCI structured and configured to control operation of the rechargeable battery charging apparatus; a user interface connected to the MCI, the user interface structured and configured to display one or more functions or modes of the rechargeable battery charging apparatus; and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the deeply discharged battery being a lead acid battery.

[0034] The subject matter described herein relates to a rechargeable battery charging device for charging a deeply discharged battery, the device comprising or consisting of: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more parts or portions of the rechargeable battery charging device, the MCI structured and configured to control an operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface structured and configured to display one or more functions or modes of the rechargeable battery charging device; and a controller structured and configured to control charging of the deeply discharged battery, the controller having a force mode that charges the deeply discharged battery even when the battery voltage is near 0 volts, the deeply discharged battery being an over-discharged lithium ion battery having an open battery management system (BMS). [Brief description of the drawings]

[0035] [Figure 1] 1 is a perspective view of a battery charging device according to the present invention; [Diagram 2] 2 is a front view showing the battery charging device shown in FIG. [Diagram 3] FIG. 3 is a front view of the power cord assembly with battery cable and battery clamp and the battery charging cable assembly of the battery charging device shown in FIGS. 1 and 2. [Figure 4] FIG. 13 is a front view of another battery charging cable assembly having positive and negative eyelet connectors for attachment to positive and negative battery clamps, respectively, or for direct attachment to the positive and negative terminals, respectively, of a deeply discharged battery. [Diagram 5]11 is a flow chart illustrating an example embodiment of enforcement mode features and operation. [Figure 6] 1 is a perspective view of another battery charging device according to the present invention with the power cord and battery charging cable assembly detached; [Figure 7] FIG. 7 is a front view of the battery charging device of FIG. 6 with the battery charging cable assembly having the battery clamp attached. [Figure 8] FIG. 7 is a functional block diagram of the battery charging device shown in FIG. [Figure 9A-1] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9A-2] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9A-3] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9A-4] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9B-1] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9B-2] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9B-3] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9B-4] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9C-1] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9C-2] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 9C-3] 7 is a circuit schematic diagram of an exemplary embodiment of the battery charging device shown in FIG. 6. [Figure 10] 7 is a perspective view of the battery charging device of FIG. 6 showing various features of the indicator 114. FIG. [Figure 11]FIG. 11 is a top view of a battery cable assembly for use with the battery charging device shown in FIGS. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] A battery charging device 310 according to the present invention is shown in FIGS.

[0037] The battery charging device 310 comprises a housing or enclosure 312 which contains the electronic components of the battery charging device 310, an electronic display 314 (i.e., a graphic user interface (GUI)), an A / C input port 316 into which an A / C power cord 318 having an input plug 320 and an A / C plug 322 is plugged, and an output port 324 into which a battery cable assembly 326 having an output plug 328 and a male plug connector 330 is plugged.

[0038] 3 has a female plug connector 334 located at one end, and a positive battery clamp 336 and a negative battery clamp 338 located at the other end. The male plug connector 330 of the battery cable assembly 326 is detachably connected to the female plug connector 334 of the battery cable assembly 332.

[0039] Alternatively, a battery cable assembly 332' (FIG. 4) includes a female plug connector 334' at one end and a positive battery cable eyelet connector 336 and a negative battery cable eyelet connector 338 at the other end. The positive battery cable eyelet connector 336 can be connected to a positive battery clamp or directly to the positive terminal of a deeply discharged battery. The negative battery cable eyelet connector 338 can be connected to a negative battery clamp or directly to the negative terminal of a deeply discharged battery. The eyelet connectors 336 and 338 provide a more permanent connection to a deeply discharged battery than a battery clamp pair.

[0040] The electronic display 314 has the following functions or indicators: 1) Forced mode LED314A; 2)Charge level LED314B; 3)Standby LED314C; 4) "Push & Hold" voltage divider 314D; 5) 12V Lithium LED314E; 6)24VCOLD / AGMLED314F; 7)24V normal LED314G; 8)12VAGV+LED314H; 9)13.6V power LED3141; 10) 12V Repair LED314J; 11) 12V COLD / AGM LED 314K; 12)12V normal LED314L; 13) Mode button 314M; and 14) Error LED314N Enforcement mode functionality

[0041] A special charging mode function and method, designated "Forced Mode", allows the charger to start charging even when the battery voltage is around 0V. This allows the charger to be used to charge deeply discharged lead acid batteries or to recover deeply discharged lithium batteries with an open BMS.

[0042] Forced mode operates similarly to normal charging mode, except that for safety reasons the time is limited to a short period of time. The timeout period for Forced mode may be 5 minutes, or it may be longer or shorter depending on the application and the type and size of the battery being charged.

[0043] After the forced mode is terminated due to the specified forced mode timeout, the charger checks the battery voltage. If the battery voltage is above the normal start-up voltage threshold, the charger begins charging in its normal mode. If the battery voltage is still too low, the charger returns to standby or off mode.

[0044] In forced mode, the device operates without the usual check for low battery voltage, so this mode must be explicitly selected from the user interface, and feedback is provided to the user from the user interface that this mode has been set.

[0045] The force mode feature and method may be applied, for example, to battery charging device 310. For example, indicator 314 may include an LED 314A (FIG. 1) that indicates when the force mode feature is "on." Battery charging device 310 may be configured to automatically turn the force mode feature "on" and "off" (e.g., by properly connecting battery charging device 310 to a deeply discharged battery and turning battery charging device 310 "on" to automatically turn on the force mode feature). Alternatively, battery charging device 310 may include a switch (e.g., a button on indicator 314) to manually turn the force mode feature "on" and "off."

[0046] An exemplary forced mode flow chart for initially charging a deeply discharged battery is shown in Figure 7. The flow chart shows:

[0047] START 310 - Initially, the forced mode is standby mode.

[0048] Decision 312 - The mode button is pressed for 5 seconds and the battery voltage is less than 1V (Volts). Detect the deeply discharged battery voltage to determine if it is less than 1V. If YES, proceed to process 314. --All mode LEDs flash. If NO, return to start 310.

[0049] Process 314 - All mode LEDs flash (mode selection).

[0050] Decision 316 – Mode Selected? If YES, proceed to decision 318 - Are the clamps connected backwards? If NO, return before decision 316.

[0051] Decision 318 - Are the clamps connected backwards? If YES, proceed to process 320 - polarity reversal LED is turned on. If NO, proceed to decision 322 - Is the battery voltage above the protection voltage?

[0052] Process 320 - Polarity Reversal LED On Decision 322 - Is the battery voltage above the protection voltage? If YES, proceed to process 326 - High Voltage LED is turned ON If NO, go to process 330 - Force mode is activated. Track live voltage at clamps (even when unplugged) and fuel gauge style LED. Timeout in 5 minutes.

[0053] Decision 324 – Is the clamp (battery) disconnected? If YES, return to start 310. If NO, return to before decision 324.

[0054] Process 326 - High Voltage LED On

[0055] Decision 328 – Outside OVP Conditions? If YES, return to start 310. If NO, return before decision 328.

[0056] Process 330 - Force mode is started, tracking live voltage at the (battery) clamps (even when unplugged) and fuel gauge style LED, times out after 5 minutes.

[0057] Another battery charging device 110 according to the present invention is shown in FIGS.

[0058] Battery charging device 110 includes a housing or casing 112 that contains the electronic components of battery charging device 110, an electronic display 114 (i.e., a graphic user interface (GUI)), a positive battery cable 116 having a positive battery clamp 118 (FIG. 2), and a negative battery cable 120 having a negative battery clamp 122 (FIG. 2).

[0059] FIG. 3 illustrates a functional block diagram of a battery charging device (e.g., a handheld jump starter) according to one aspect of the present invention. At the heart of the handheld jump starter is a lithium polymer battery pack 32. This battery pack stores enough energy to jump start the engine of a vehicle powered by a conventional 12 volt lead acid battery or a valve regulated lead acid battery. In one exemplary embodiment, the high surge lithium polymer battery pack includes three 3.7V, 2666mAh lithium polymer batteries in a 351P configuration. The resulting battery pack provides 11.1V, 2666Ah (8000Ah at 3.7V, 29.6Wh). The continuous discharge current is 25C (or 200 amps) and the burst discharge current is 50C (or 400 amps). The maximum charge current of the battery pack is 8000mA (8 amps).

[0060] A programmable microcontroller unit (MCU) 1 receives various inputs and generates information and control outputs. The programmable MCU 1 provides flexibility to the system by allowing functionality and system parameters to be updated without hardware changes. According to one exemplary embodiment, an 8-bit microcontroller with 2K x 15 bits of flash memory is used to control the system. One such microcontroller is the HT67F30 sold by Holtek Semiconductor Inc.

[0061] The vehicle battery reverse connection sensor 10 monitors the polarity of the vehicle battery 72 when the handheld jump starter device is connected to the vehicle's electrical system. As described below, if the terminals of the battery 72 are connected to the wrong terminals of the jump starter device, the jump starter device will protect the lithium battery pack from being connected to the vehicle battery 72. The vehicle battery isolation sensor 12 detects whether the vehicle battery 72 is connected to the jump starter device and protects the lithium battery pack from being connected to the output terminals of the jump starter device unless a healthy battery (e.g., a rechargeable battery) is present at the output terminals.

[0062] Only when the MCU 1 determines that a vehicle battery is present (in response to the detection signal provided by the isolation sensor 12) and connected with the correct polarity (in response to the detection signal provided by the reverse connection sensor 10) is the handheld jump starter lithium battery electrically switched into the vehicle's electrical system by the smart switch FET circuit 15. The lithium battery temperature sensor 20 monitors the temperature of the lithium battery pack 32 to detect overheating due to high ambient temperature conditions or excessive current draw during jump starting. The lithium battery voltage measurement circuit 24 monitors the voltage of the lithium battery pack 32 to prevent the voltage potential from becoming too high when charging or too low when discharging.

[0063] The lithium battery reverse charge protection diode 28 prevents the charging current being supplied to the vehicle battery 72 from flowing back from the vehicle's electrical system to the lithium battery pack 32. The flashlight LED circuit 36 ​​is provided to provide a flashlight function to illuminate under the hood of the vehicle in dark conditions, as well as SOS and strobe lighting functions for safety if the vehicle becomes stuck in a potentially dangerous location. The voltage regulator 42 regulates the internal operating voltage of the microcontroller and sensors. The on / off manual mode and flashlight switch 46 allows the user to control powering on the handheld jump starter device, control manual override operation when the vehicle has no battery, and control the flashlight function. The manual button only functions when the jump starter device is powered on. This button allows the user to jump start the vehicle when there is no battery or when the battery voltage is low enough that it cannot be automatically detected by the MCU. To prevent accidental activation of manual mode, if the user presses and holds the manual override button for a predetermined period of time (e.g., 3 seconds), the internal lithium ion battery power source is switched to the vehicle battery connection port. The only exception to the manual override is if the vehicle battery is connected backwards. If the car battery is connected backwards, the internal lithium battery power source is not switched to the vehicle battery connection port.

[0064] The USB charging circuit 52 converts power from any USB charger source into charging voltage and current for charging the lithium battery pack 32. The USB output 56 provides a USB portable charger for charging smartphones, tablets, and other rechargeable electronic devices. The operation indicator LED 60 provides a visual indication of the capacity status of the lithium battery, as well as the activation status of the switch (indicating that power is being supplied to the vehicle's electrical system). The detailed operation of the handheld jump starter device will now be described with reference to the schematic diagrams of Figures 2A-2C. As shown in Figure 2A, the microcontroller unit 1 is at the center of all inputs and outputs. The reverse battery sensor 10 comprises an optically coupled isolator phototransistor (4N27) connected to the terminals of the vehicle battery 72 at input pins 1 and 2, with a diode D8 in the lead conductor of pin 1 (associated with the negative terminal CB-), and when the battery 72 is connected to the terminals of the jump starter device with the correct polarity, the optocoupler LED 11 does not conduct current and is therefore off, providing a "1" or high output signal to the MCU 1. The vehicle battery isolation sensor 12 comprises an optically coupled isolator phototransistor (4N27) connected to the terminals of the vehicle battery 72 at input pins 1 and 2, with a diode D7 in the lead conductor of pin 1 (associated with the positive terminal CB+) so that when the battery 72 is connected to the jump starter device terminals with the correct polarity, current flows through optocoupler LED11A, which is therefore on and provides a “0” or low output signal to the MCU, indicating the presence of a battery across the jumper output terminals of the handheld jump starter device.

[0065] When the vehicle battery 72 is connected to the handheld jump starter device with reversed polarity, the optocoupler LED11 of the reverse connection sensor 10 will have a current flow through it, providing a "0" or low level signal to the microcontroller unit 1. Furthermore, when no battery is connected to the handheld jump starter device, the optocoupler LED11A of the isolation sensor 12 will have no current flow through it, and will therefore be off, providing the MCU a "1" or high output signal, indicating that no battery is connected to the handheld jump starter device. Using these particular inputs, the microcontroller software of the MCU1 can determine when it is safe to turn on the smart switch FET15, thereby jumpering the lithium battery pack to the jump starter device. This allows the MCU1 to prevent the smart switch FET15 from being in an on state, preventing sparking / short circuiting of the lithium battery pack, when the vehicle battery 72 is not connected to the jump starter device at all, or is connected with reversed polarity.

[0066] As shown in FIG. 2B, the FET smart switch 15 is driven by the output of the microcontroller 1. The FET smart switch 15 includes three parallel FETs (Q15, Q18, and Q19) and distributes power from the lithium battery pack to the FETs. When the microcontroller output is driven to logic low, the resistance of each FET 16 is high, and therefore no current flows from the negative contact 17 of the internal lithium battery to the negative contact of the vehicle battery 72. When the microcontroller output is driven to logic high, the resistance of the FETs 16 (Q15, Q18, and Q19) is low, and current can freely flow from the negative contact 17 of the internal lithium battery pack (LB-) to the negative contact (CB-) of the vehicle battery 72. In this way, the microcontroller software controls the connection between the internal lithium battery pack 32 and the vehicle battery 72 for jump starting the vehicle engine. Returning to FIG. 2A, the internal voltage of the lithium battery pack can be accurately measured using the circuit 24 and one of the analog digital inputs of the microcontroller 1. Circuit 24 is designed to sense when the main 3.3V regulator 42 voltage is on and turn transistor 23 on when regulator 42 voltage is on. When current flows through transistor 23, FET 22 turns on, which provides a conductive path for the internal lithium battery positive node (LB+) to voltage divider 21, allowing the lower range voltage to be sent to the microcontroller for reading. Using this input, the microcontroller software can determine if the lithium battery voltage is getting too low during a discharge operation or too high during a charge operation and take appropriate action to prevent damage to the electronics.

[0067] Still referring to FIG. 2A, two Negative Temperature Coefficient (NTC) devices 20 allow for accurate measurement of the internal temperature of the lithium battery pack 32. These devices are devices that reduce resistance as the temperature rises. The circuit is a voltage divider that provides the results to two analog-to-digital (A / D) inputs on the microcontroller 1. The microcontroller software then determines when the temperature of the internal lithium battery is too high for a jump start, providing an additional layer of safety to the design. The main voltage regulator circuit 42 is designed to convert the voltage of the internal lithium battery to a regulated voltage of 3.3 volts. This voltage is used to power the internal operation of the microcontroller 1 and other components of the jump starter device. Three lithium battery reverse charge protection diodes 28 (see FIG. 2B) are positioned to ensure that current from the internal lithium battery pack 32 flows only to the vehicle battery 72 and not from the vehicle battery to the internal lithium battery. In this way, another level of safety is provided since the internal lithium battery cannot be reverse charged (and thereby damaged) by the car's electrical system charging from the alternator. The main power on switch 46 (FIG. 2A) is a combination that allows double pole double throw operation that can turn the product's off state on with one press and turn it off with an on state. The circuit also uses a microcontroller output 47 to "keep alive" the power when activated by the on switch. When the switch is pressed, the microcontroller drives this output to a high logic level to keep the power on when the switch is released. In this way, the microcontroller maintains control of when to turn the power off if the on / off switch is activated again or if the lithium battery voltage gets too low. The microcontroller software also includes a timer that turns the power off after a predetermined period of non-use (e.g., 8 hours). The flashlight LED circuit 45 shown in FIG. 2B controls the operation of the flashlight LED. Two outputs from the microcontroller 1 are dedicated to two separate LEDs.Thus, when used for strobe or SOS patterns, the LEDs can be independently controlled by software, providing yet another safety feature to the jump starter device. The LED indicators provide the necessary feedback for the operator to understand what is happening with the product. Four separate LEDs 61 (FIG. 2A) are controlled by corresponding outputs of the microcontroller 1 to provide a charge indication for the internal lithium battery. Each LED is controlled in a "fuel gauge" fashion with charge indications of 25%, 50%, 75% and 100% (red, red, yellow, green). The LED indicator 63 (FIG. 2B) provides a visual warning to the user if the vehicle battery 72 is connected in reverse polarity. The "boost" and on / off LEDs 62 provide a visual indication when the jump starter device is providing jump start power and when the jump starter device is on, respectively.

[0068] The USB output 56 circuit (FIG. 2C) is provided to provide a USB output from the internal lithium battery pack 32 for charging a portable electronic device such as a smartphone. A control circuit 57 from the microcontroller 1 turns the USB output 56 on and off under software control to prevent the capacity of the internal lithium battery from dropping too low. The USB output is brought out to the outside of the device via a standard USB connector 58. This connector includes a standard voltage divider required to enable charging of the specific smartphone that requires this output. The USB charging circuit 52 allows the internal lithium battery pack 32 to be charged with a standard USB charger. The input for this charging is a standard micro USB connector 48, so that a standard cable can be used. The 5V potential provided by the standard USB charger is up-converted by the DC-DC converter 49 to the 12.4VDC voltage required to charge the internal lithium battery pack. The DC-DC converter 49 can be turned on and off by the output from the microcontroller 1 via the circuit 53.

[0069] In this way, the microcontroller software can turn off charging if too much battery voltage is measured by the A / D input 22. As an added safety measure to avoid overcharging the internal lithium battery, a lithium battery charge controller 50 is used to ensure charge balancing of the internal lithium battery cells 51. This controller also provides a double safety measure to avoid over-discharging the internal lithium battery.

[0070] FIG. 5 shows a handheld device 110 according to an exemplary embodiment of the present invention. 112 is a housing. 114 is an indicator. 114A is a power-on switch. 114B is an LED "fuel gauge" style indicator. 114C is a "boost on" indicator that indicates that power is being applied to the 12V output port 122, and 114D is a "reverse" indicator that indicates that the vehicle battery is connected with improper polarity. 114E is a "power on" indicator that indicates that power is being applied to operate the device. 118 is a USB input port for charging the internal Li-ion battery. 118A is a removable cover for the USB input port 118, and 120 is a USB output port for powering other portable devices such as smartphones, tablets, music players, and other electronic devices from the internal Li-ion battery. 120A is a removable cover for the USB output port 120. Reference numeral 122 denotes a 12V output port that can be connected to a cable device 210, which will be described later.

[0071] 6 shows a jumper cable device 210 that is specifically designed for use with the handheld device 110. The device 210 has a plug 212 that is configured to plug into the 12V output port 122 of the handheld device 110. A positive battery cable 214 and a negative battery cable 218 are integrated into the plug 212 and are connected to the positive battery clamp 216 and the negative battery clamp 220, respectively, via a ring connector 216A and a ring connector 220A. As shown on the clamps, the 12V output port 122 and plug 212 are shaped so that the plug 212 can only fit into the 12V output port 122 in a specific orientation to ensure that the positive battery clamp 216 and the negative battery clamp 220 are not mixed up.

[0072] Additionally, ring terminals 216A and 216B can be detachably connected directly to the terminals of a vehicle battery, with battery clamps 216, 229 removed from battery cables 214, 218, respectively. This feature can be used, for example, to permanently attach battery cables 214 and 218302b to a vehicle battery. In the event that the battery voltage becomes depleted or discharged, simply insert plug 212 into 12V output port 122 to properly connect handheld jump starter device 110 to the depleted or discharged vehicle battery.

[0073] It will be apparent to those skilled in the art that the invention thus described may be modified in various ways without departing from the spirit or scope of the invention, and all such modifications are intended to be encompassed within the scope of the appended claims. [Explanation of symbols]

[0074] 1 Microcontroller Unit 10 Reverse Battery Sensor 11 Optocoupler LED 12 Vehicle Battery Isolation Sensor 15 Smart Switch FET Circuits 16,22 FET 17 Internal Lithium Battery Pack Negative Contact 20 Lithium-ion battery temperature sensor 23 Transistor 24 Lithium battery voltage measurement circuit 28 Lithium battery reverse charge protection diode 32 Lithium Polymer Battery Pack 42 Main 3.3V regulator 45 Flashlight LED circuit 46 On / Off Manual Mode and Flashlight Switch 47 Microcontroller Output 48 Micro USB Connector 49 DC-DC Converters 50 Lithium Battery Charge Controller 51 Internal Lithium Battery Cells 52 USB charging circuit 56 USB output 57 Control circuit 58 USB connector 60 Operation indicator LED 61 LED 62 "Boost" and On / Off LED 63 LED indicators 110 Handheld Devices 114 Display 118 USB input port 120 USB output port 122 12V output port 210 Jumper cable device 216,229 Positive Battery Clamp 216A, 216B Ring terminal 220 Negative battery clamp 310 Battery charging equipment 314 Electronic display 316 A / C input port 318 A / C power cord 320 Input Plug 322 A / C plug 324 output port 326 Battery Cable Assembly 328 Output Plug 330 Male Plug Connector 334, Female plug connector 336 Positive Battery Cable Eyelet Connector 338 Negative Battery Cable Eyelet Connector

Claims

1. A method for charging a deeply discharged battery using a battery charging device, comprising: receiving user input defining a user selection of an enforcement mode; measuring an output voltage of the deeply discharged battery using the battery charging device; based on the user input and a measurement indicating the output voltage is below a minimum threshold, causing the battery charging device to enter the forced mode to automatically charge the deeply discharged battery with the battery charging device without a low voltage safety check that would prevent the battery charging device from charging when no battery voltage is detected; and, preventing the battery charger from entering the forced mode if measurements indicate that the output voltage is above the minimum threshold. method.

2. The minimum threshold is 1 V (volt); The method of claim 1.

3. the deeply discharged battery is charged by the battery charging device in the forced mode for a predetermined amount of time; The method of claim 1.

4. The predetermined amount of time is 5 minutes. The method according to claim 3.

5. Charging of the deeply discharged battery in the forced mode is terminated when a predetermined amount of time is reached. The method of claim 1.

6. further comprising measuring the deeply discharged battery after the forced mode is terminated. The method according to claim 5.

7. When the forced mode is terminated and the deeply discharged battery output voltage is measured, if the deeply discharged battery exceeds a normal start-up voltage threshold, the battery charging device starts charging in a normal mode. The method according to claim 6.

8. After the forced mode is terminated and the deeply discharged battery output voltage is measured, if the deeply discharged battery voltage is too low, the battery charger returns to a standby mode or an off mode. The method according to claim 7.

9. The deeply discharged battery is a lead acid battery. The method according to any one of claims 1 to 8.

10. The deeply discharged battery is a deeply discharged lithium ion battery having an open battery management system (BMS). The method according to any one of claims 1 to 8.

11. 1. A rechargeable battery charging device for charging a deeply discharged battery, comprising: a rechargeable battery having a positive terminal and a negative terminal; A positive battery cable connected or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected or connectable to the negative terminal of the rechargeable battery; a detector for measuring the output voltage of the deeply discharged battery; a microcontroller connected to one or more parts or portions of the rechargeable battery charging device and structured and configured to control the operation of the rechargeable battery charging device; a user interface coupled to the microcontroller, the user interface structured and configured to accept user input and to indicate one or more functions or modes of the rechargeable battery charging device; the microcontroller structured and configured to control charging of the deeply discharged battery; The microcontroller comprises: accepting user input indicating a user selection of the enforcement mode; measuring the output voltage of the deeply discharged battery; If the forced mode is selected and the measured output voltage is below a minimum threshold, causing the rechargeable battery charger to enter the forced mode to automatically charge the deeply discharged battery using the rechargeable battery charger without a low voltage safety check that would prevent charging by the rechargeable battery charger when no battery voltage is detected; and, and configured to prevent the rechargeable battery charger from entering the forced mode if measurements indicate that the output voltage is above the minimum threshold. Device.

12. The minimum threshold is 1 V (volt); 12. The apparatus of claim 11.

13. the forced mode is configured to operate for a predetermined amount of time; 13. The apparatus of claim 12.

14. The predetermined amount of time is 5 minutes.

14. The apparatus of claim 13.

15. after the forced mode is terminated due to the predetermined amount of time having been consumed, the rechargeable battery charger measures the voltage of the deeply discharged battery.

14. The apparatus of claim 13.

16. When the deeply discharged battery exceeds a normal start-up voltage threshold, the rechargeable battery charger starts charging in a normal mode.

16. The apparatus of claim 15.

17. If the deeply discharged battery voltage is too low, the rechargeable battery charger returns to standby mode or off mode.

16. The apparatus of claim 15.

18. the user interface is structured and arranged to allow a user to select the enforcement mode; 13. The apparatus of claim 12.

19. the user interface is configured to provide user feedback when the rechargeable battery charging device is in the forced mode.

20. The apparatus of claim 18.

20. The user feedback is provided by illuminating a light emitting diode (LED).

20. The apparatus of claim 19.

21. The deeply discharged battery is a lead acid battery. Apparatus according to any one of claims 12 to 20.

22. The deeply discharged battery is a deeply discharged lithium ion battery having an open battery management system (BMS). Apparatus according to any one of claims 12 to 20.

Images