Battery charging device with temperature sensor for providing temperature compensation during charging and method of measuring temperature of depleted or discharged battery to compensate for charging of battery charging device

Abstract

A battery charging apparatus for charging a discharged or depleted battery, the apparatus comprising one or more temperature sensors for measuring or approximating a temperature of the discharged or depleted battery; and a controller receiving input signals from the one or more temperature sensors to compensate for charging operations of the battery charging apparatus.

Description

TECHNICAL FIELD

[0001] The present application relates to a battery charging device with a temperature sensor, for example an ambient temperature sensor, and temperature compensation during charging of a depleted or discharged battery, and a method of measuring the temperature of a battery in a battery charging device. BACKGROUND

[0002] The voltage of a lead-acid battery has a strong dependence on temperature. A typical lead-acid battery can have a temperature dependence of -3.3 mV / °C / cell with respect to 25°C. Thus, a 12V battery in a 50°C environment will have a voltage difference of (-3.3 mV / °C / cell) x (6 cells) x (50°C - 25°C) = -495 mV compared to the same battery in a 25°C environment.

[0003] The voltage difference caused by temperature can have a significant impact on the effectiveness of charging when charging a battery. A charger optimized at 25°C will overcharge hot batteries and undercharge cold batteries.

[0004] Thus, there is a need to provide an improved battery charger configured to accommodate changes in temperature, for example changes in ambient temperature, when charging a discharged or depleted battery. In particular, there is a need to provide a simple and cost effective way or method to approximate the temperature of a discharged or depleted battery in order to achieve temperature compensation by the battery charger.

[0005] In addition, "smart" battery chargers, i.e. smart chargers, implement various protections to ensure proper use of the smart charger. One of the protections typically implemented is to measure the battery voltage before starting a charging cycle. If the battery voltage is too low, the smart battery charger will not start charging.

[0006] Under normal use, a typical lead-acid battery will never get low enough to prevent a smart charger from charging. However, in the case where a current load is applied to the battery and left connected, it is possible to encounter a battery with a voltage close to 0V. In this case, a typical smart battery charger will not start a charging cycle.

[0007] Smart chargers use battery packs that include lithium-ion batteries and a battery management system (BMS) configured to disconnect the lithium-ion battery from the external battery terminals in the event of an error. When the lithium-ion battery is internally disconnected, the voltage will measure 0V at the external battery terminals. In some BMS implementations, after a condition of over-discharge, the external battery voltage will remain at 0V even when the error condition is removed. An external voltage must be applied to restore the battery. However, a typical smart battery charger will not apply a charging voltage as the smart battery charger will not start a charging cycle if it detects a battery voltage at 0V.

[0008] Accordingly, there is a need for an intelligent battery charger, system, and method that allows an intelligent battery charger to charge a deeply discharged battery without completely eliminating low voltage protection. SUMMARY

[0009] The present application relates to a battery charging device configured with temperature compensation. For example, the battery charging device includes one or more temperature sensors for sensing the temperature of a depleted or discharged battery, and the battery charging device is configured to provide temperature compensation. In addition, the present application relates to a system and method of measuring the temperature of a battery to provide temperature compensation in a battery charging device.

[0010] For example, the battery charging device is configured to modify its charge voltage threshold based on the temperature of the battery, such as the ambient temperature of a discharged or depleted battery.

[0011] One of the challenges in implementing temperature compensation is the location of the temperature sensor for measuring the temperature of the battery. Ideally, the temperature sensor would be located on the discharged or depleted battery. However, this requires an additional set of wiring, and a method of attaching the sensor to the discharged or depleted battery. This can increase cost, reduce reliability, and increase complexity, all of which are undesirable.

[0012] The temperature sensor can be located within the housing or enclosure of the battery charging device. Since the battery charging device is located in the same environment as the battery, the temperature measured within the battery charger can be considered to be close to the temperature of the battery. However, this approach can be problematic since the temperature inside the battery charging device is elevated by the heat generated by the internal electronics.

[0013] To avoid the heated environment within the housing or enclosure of the battery charging device generated by the internal electronics, for example, the temperature sensor can be located in a separate compartment that is internal or external to the housing or enclosure, that is separate and insulated from the compartment that houses the internal electronics (e.g., a separate compartment for the temperature sensor and a compartment for the electronics that are injection molded in a plastic housing or enclosure).

[0014] As another example, the one or more temperature sensors can be located on a battery cable assembly (e.g., a battery cable assembly that includes a plug, a cable, a connector, and / or a battery clamp). In particular, the one or more temperature sensors can be located on or associated with the plug, the cable, the connector, and / or the battery clamp of the battery cable assembly.

[0015] The battery charging device can be provided with one or more temperature sensors (e.g., ambient battery sensors). Alternatively, or additionally, the battery cable assembly can be provided with one or more temperature sensors. Providing multiple temperature sensors allows for sensing and measuring one or more temperatures of one or more components or assemblies of the battery charging device, as well as temperature differences between one or more components or assemblies of the battery charging device, the battery cable assembly, and / or a discharged or depleted battery.

[0016] The one or more temperature sensors can be wired to internal electronics of the battery charging device (e.g., to a microcontroller) and / or wirelessly linked to the internal electronics.

[0017] For example, the temperature sensor measures the temperature at the beginning of the charging cycle. The temperature measured at this time is applied to the temperature compensation algorithm and used throughout the charging cycle. Since the temperature is measured before the charging cycle begins, the temperature rise due to the internal electronics of the battery charger can be negligible. The temperature measured in this way can be considered a reasonable approximation of the actual battery temperature.

[0018] A failsafe method is included in the battery charger to prevent overcharging or undercharging the battery in the event of a temperature sensor failure. If the measured temperature exceeds a safe range due to a sensor failure or damage, the charger holds the charging voltage within a safe level.

[0019] For example, a battery charging device (e.g., a smart battery charger) according to the present application can be a portable and automatic battery charger for 12V and 24V lead-acid batteries (e.g., wet, gel, MF, EFB, AGM batteries) and / or lithium-ion batteries. For example, the smart battery charging device is constructed and arranged for charging automobiles, boats, RVs, SUVs, diesel trucks, motorcycles, ATVs, snowmobiles, personal watercraft, lawn mowers, and other vehicles or equipment. The smart battery charging device can also be used as a battery maintainer, for example, to maintain both a starter battery and a fully charged deep cycle battery. The smart battery charging device can monitor the activity of the battery, for example, for safe and efficient charging without any overcharging. For example, the smart battery charging device can include a built-in battery desulfator to rejuvenate underperforming batteries.

[0020] The present application includes a battery charging device (e.g., smart battery charger) that includes or consists of a special charging mode or feature designated as "forced mode" (e.g., trademarked Force Mode) that allows the battery charging device to begin charging a deeply discharged battery even if the battery voltage is close to 0V (i.e., zero volts). This allows the battery charging device to be used to charge deeply discharged lead-acid batteries, and / or to recover over-discharged lithium batteries with open BMS. For example, the battery charging device can be configured to automatically start the forced mode, or the user can force the battery charging device to start the forced mode (e.g., by pressing a force mode button).

[0021] The forced mode feature allows the battery charging device to enter a battery charging mode when the battery voltage of a deeply discharged battery (e.g., a deeply discharged vehicle battery) is below a minimum threshold. The purpose is to allow the battery charging device to be able to charge, for example, deeply discharged lead-acid batteries, and to be able to reset the battery management system (BMS) in an over-discharged lithium-ion battery of the battery charging device.

[0022] The forced mode operates as a normal charging mode except that it is limited to a short time period for safety reasons. The timeout period for the forced mode can be, for example, five (5) minutes, or can be longer or shorter depending on the specific application, type, and size of the deeply discharged battery being charged.

[0023] After the forced mode terminates due to the designated forced mode time expiring, the battery charging device will check the battery voltage. If the battery voltage is above the normal start voltage threshold, the battery charging device will start charging in its normal mode. If the battery voltage is still too low, the battery charging device will return to its standby or off mode.

[0024] Because the forced mode operates without the normal low battery voltage check, the user interface will need to explicitly select the mode and provide user feedback that it is in that mode.

[0025] According to an aspect of the present application, the battery charging device arranged for jump starting a deeply discharged vehicle battery includes: an internal power source; a selectable output port having positive and negative polarity outputs; a vehicle battery isolation sensor coupled to the positive and negative polarity output circuit configured to detect the presence of a vehicle battery connected between the positive and negative polarity outputs; a reverse polarity sensor coupled to the circuit having positive and negative polarity outputs configured to detect the polarity of a vehicle battery connected between the positive and negative polarity outputs; 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 provide output signals to the power FET switch such that in response to signals from the sensors indicating the presence of a vehicle battery at the output port and the proper polarity connection of the positive and negative terminals of the vehicle battery to the positive and negative outputs, the power FET switch is turned on to connect the internal power source to the output port.

[0026] According to another aspect of the present application, the internal power source is a rechargeable lithium ion battery pack.

[0027] According to yet another aspect of the present application, there is provided a charging or jump cable device having: a plug configured to be inserted into an output port of a hand-held battery charger voltage regulator device having an internal power source; a pair of cables integrated with the plug at one respective end of the plug; the pair of cables configured to be connected to terminals of a battery at the other respective end of the pair of cables, respectively.

[0028] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device including one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device including a controller receiving input signals from the one or more temperature sensors for compensating a charging operation of the battery charging device.

[0029] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device including one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device including a controller receiving input signals from the one or more temperature sensors for compensating a charging operation of the battery charging device, wherein the charging operation is controlled by the one or more input signals from the one or more temperature sensors received by the controller of the battery charging device.

[0030] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising or consisting of one or more temperature sensors for measuring or approximating a temperature of the discharged or depleted battery; and the device comprising a controller receiving input signals from the one or more temperature sensors to compensate for a charging operation of the battery charging device, wherein the one or more temperature sensors are a plurality of temperature sensors.

[0031] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising or consisting of one or more temperature sensors for measuring or approximating a temperature of the discharged or depleted battery; and the device comprising a controller receiving input signals from the one or more temperature sensors to compensate for a charging operation of the battery charging device, wherein the one or more temperature sensors are connected to or associated with the battery charging device.

[0032] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising or consisting of one or more temperature sensors for measuring or approximating a temperature of the discharged or depleted battery; and the device comprising a controller receiving input signals from the one or more temperature sensors to compensate for a charging operation of the battery charging device, wherein the one or more temperature sensors are connected to or associated with the battery charging device, and wherein the one or more temperature sensors are connected to or associated with a housing or casing of the battery charging device.

[0033] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising or consisting of one or more temperature sensors for measuring or approximating a temperature of the discharged or depleted battery; and the device comprising a controller receiving input signals from the one or more temperature sensors to compensate for a charging operation of the battery charging device, wherein the one or more temperature sensors are connected to or associated with the battery charging device, and wherein the one or more temperature sensors are connected to or associated with a battery cable assembly of the battery charging device.

[0034] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising or consisting of one or more temperature sensors for measuring or approximating a temperature of the discharged or depleted battery; and the device comprising a controller receiving input signals from the one or more temperature sensors to compensate for charging operations of the battery charging device, wherein the one or more temperature sensors are connected to or associated with the battery charging device, and wherein the one or more temperature sensors are connected to or associated with a housing or casing of the battery charging device and a battery cable assembly of the battery charging device.

[0035] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising or consisting of one or more temperature sensors for measuring or approximating a temperature of the discharged or depleted battery; and the device comprising a controller receiving input signals from the one or more temperature sensors to compensate for charging operations of the battery charging device, the device further comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected to or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected to 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 components or parts of the rechargeable battery charging device, the MCI being configured and arranged to control operations of the rechargeable battery charging device; a user interface connected to the MCI, the user interface being configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage is close to 0 volts.

[0036] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device comprising a controller that receives input signals from the one or more temperature sensors to compensate for the charging operation of the battery charging device, the device further comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected to or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected to or connectable to the negative terminal of the rechargeable battery; a detector for measuring the output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage is close to 0 volts, wherein the force mode is configured to work for a predetermined period of time.

[0037] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device comprising a controller that receives input signals from the one or more temperature sensors to compensate for the charging operation of the battery charging device, the device further comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected to or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected to or connectable to the negative terminal of the rechargeable battery; a detector for measuring the output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage is close to 0 volts, wherein the force mode is configured to work for a predetermined period of time, and wherein the predetermined period of time is 5 minutes.

[0038] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device comprising a controller that receives input signals from the one or more temperature sensors to compensate for charging operations of the battery charging device, the device further 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 programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage approaches 0 volts, wherein the force mode is configured to operate for a predetermined period of time, wherein after the force mode is terminated due to the expiration of the predetermined period of time, the rechargeable battery charging device will measure the deeply discharged battery voltage.

[0039] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device comprising a controller that receives input signals from the one or more temperature sensors to compensate for charging operations of the battery charging device, the device further 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 programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage approaches 0 volts, wherein the force mode is configured to operate for a predetermined period of time, wherein after the force mode terminates due to expiration of the predetermined period of time, the rechargeable battery charging device will measure the deeply discharged battery voltage, and wherein if the deeply discharged battery is above a normal start voltage threshold, the rechargeable battery charging device will begin charging in a normal mode.

[0040] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device comprising a controller that receives input signals from the one or more temperature sensors to compensate for the charging operation of the battery charging device, the device further 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 programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage is close to 0 volts, wherein the force mode is configured to work for a predetermined period of time, wherein after the force mode is terminated due to the expiration of the predetermined period of time, the rechargeable battery charging device will measure the deeply discharged battery voltage, wherein if the deeply discharged battery is above a normal start voltage threshold, the rechargeable battery charging device will start charging in a normal mode, and wherein if the deeply discharged battery voltage is too low, the rechargeable battery charging device will return to a standby mode or a shut down mode.

[0041] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device including one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device including a controller that receives input signals from the one or more temperature sensors to compensate for charging operations of the battery charging device, the device further including: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected to or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected to or connectable to the negative terminal of the rechargeable battery; a detector for measuring the output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage approaches 0 volts, wherein the force mode is configured to operate for a predetermined period of time, wherein the user interface is configured and arranged to allow a user to select the force mode.

[0042] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device including one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device including a controller that receives input signals from the one or more temperature sensors to compensate for charging operations of the battery charging device, the device further including: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected to or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected to or connectable to the negative terminal of the rechargeable battery; a detector for measuring the output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage approaches 0 volts, wherein the force mode is configured to operate for a predetermined period of time, wherein the user interface is configured and arranged to allow a user to select the force mode, and wherein the user interface is configured to provide user feedback if the rechargeable battery charging device is in the force mode.

[0043] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device comprising a controller that receives input signals from the one or more temperature sensors to compensate for the charging operation of the battery charging device, the device further 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 programmable microcontroller unit (MCU) connected to one or more components or parts of the rechargeable battery charging device, the MCU configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCU, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage approaches 0 volts, wherein the force mode is configured to work for a predetermined period of time, wherein the user interface is configured and arranged to allow a user to select the force mode, wherein the user interface is configured to provide user feedback if the rechargeable battery charging device is in the force mode, and wherein the user feedback is provided by illuminating a light emitting diode (LED).

[0044] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device comprising a controller that receives input signals from the one or more temperature sensors to compensate for the charging operation of the battery charging device, the device further comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected to or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected to or connectable to the negative terminal of the rechargeable battery; a detector for measuring the output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage is near 0 volts, wherein the deeply discharged battery is a lead-acid battery.

[0045] The presently described subject matter relates to a battery charging device for charging a discharged or depleted battery, the device comprising one or more temperature sensors for measuring or approximating the temperature of the discharged or depleted battery; and the device comprising a controller that receives input signals from the one or more temperature sensors to compensate for the charging operation of the battery charging device, the device further comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected to or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected to or connectable to the negative terminal of the rechargeable battery; a detector for measuring the output voltage of the deeply discharged battery; a programmable microcontroller unit (MCI) connected to one or more components or parts of the rechargeable battery charging device, the MCI configured and arranged to control the operation of the rechargeable battery charging device; a user interface connected to the MCI, the user interface configured and arranged to display one or more functions or modes of the rechargeable battery charging device; and a controller configured and arranged to control the charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage is near 0 volts, wherein the deeply discharged battery is an over-discharged lithium-ion battery with an open battery management system (BMS).

[0046] The present application relates to a method for charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of the steps of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery.

[0047] The present application relates to a method for charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of the steps of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein the detected temperature is an ambient temperature of the discharged or depleted battery.

[0048] The present application relates to a method for charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of the steps of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein the temperature is detected during a specific charging mode.

[0049] The present application relates to a method for charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of the steps of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein the temperature is detected in real time during a charging operation of the battery charging device.

[0050] The present application relates to a method for charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of the steps of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein the temperature is detected over a predetermined amount of time.

[0051] The present application relates to a method for charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of the steps of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein charging of the discharged or depleted battery is terminated when a threshold temperature detected for the battery charging device is reached.

[0052] The present application relates to a method of charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein charging of the discharged or depleted battery is terminated upon detecting a temperature exceeding a threshold temperature detected for a discharged or depleted battery.

[0053] The present application relates to a method of charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein charging of the discharged or depleted battery is not initiated upon detecting a temperature exceeding a threshold temperature detected for a discharged or depleted battery.

[0054] The present application relates to a method of charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein the battery charging device measures a temperature of the battery charging device prior to a charging operation of the battery charging device.

[0055] The present application relates to a method of charging a discharged or depleted battery using a battery charging device, the method comprising or consisting of: detecting a temperature of the discharged or depleted battery; and compensating a charging operation of the battery charging device based on the detected temperature of the discharged or depleted battery, wherein the battery charging device measures a temperature of the discharged or depleted battery prior to a charging operation of the battery charging device. BRIEF DESCRIPTION OF DRAWINGS

[0056] Figure 1 is a perspective view of a battery charging device according to the present application.

[0057] Figure 2 is a front view of the battery charging device shown in Figure 1

[0058] Figure 3 is a front view of the battery charging device shown in Figure 1 and Figure 2 , showing a battery charging cable assembly with a battery cable and a battery clamp and a power cord assembly.

[0059] ​Figure 4 is a front view of a replaceable battery charging cable assembly having positive and negative eye connectors for attachment to positive and negative battery clamps or directly to positive and negative terminals of a deep discharge battery.

[0060] Figure 5 is a flow chart illustrating an example embodiment of the forced mode feature and operation.

[0061] Figure 6 is a perspective view of another battery charging apparatus according to the present application with the power cord and battery charging cable assembly detached.

[0062] Figure 7 is a perspective view of the battery charging apparatus of Figure 6 with the battery charging cable assembly attached with battery clamps.

[0063] Figure 8 is a functional block diagram of the battery charging apparatus shown in Figure 6

[0064] Figure 9 Figure 9A to Figure 9C is a schematic circuit diagram of an example embodiment of the battery charging apparatus shown in Figure 6

[0065] Figure 10 is a perspective view of the battery charging apparatus shown in Figure 6

[0066] Figure 11 is a top view of a battery cable assembly for use with the battery charging apparatus shown in Figure 6 to Figure 10 DETAILED DESCRIPTION

[0067] Figure 1 to Figure 3 A battery charging apparatus 310 according to the present application is shown in

[0068] The battery charging apparatus 310 includes a housing or case 312 that houses the electronic components of the battery charging apparatus 310, an electronic display 314 (i.e., a graphical user interface (GUI)), an A / C inlet port 316 for housing an A / C power cord assembly 318 having an inlet plug 320 and an A / C plug 322, an outlet port 324 for housing a battery cable assembly 326 having an outlet plug 328, and a male plug connector 330.

[0069] Figure 3 ​​​​Another battery cable assembly 332 is shown in FIG. 3, having a female plug connector 334 at one end and a positive battery clamp 336 and a negative battery clamp 338 at its opposite end. The male plug connector 330 of the battery cable assembly 326 is releasably connected to the female plug connector 334 of the battery cable assembly 332.

[0070] Alternatively, a battery cable assembly 332' (shown in FIG. 4) is provided with 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 its opposite end. The positive battery cable eyelet connector 336 is capable of being connected to a positive battery clamp or directly to the positive terminal of a deep discharge battery. The negative battery cable eyelet connector 338 is capable of being connected to a negative battery clamp or directly to the negative terminal of a deep discharge battery. The eyelet connectors 336 and 338 provide a more permanent type of connection to a deep discharge battery as compared to the set of battery clamps. Figure 4

[0071] The electronic display 314 includes the following features or indicators:

[0072] 1) Force Mode LED 314A;

[0073] 2) Charge Level LED 314B;

[0074] 3) Standby LED 314C;

[0075] 4) "Push and Hold" Divider 314D;

[0076] 5) 12V Lithium LED 314E;

[0077] 6) 24V Cold / AGM led 314F;

[0078] 7) 24V Standard LED 314G;

[0079] 8) 12V AGM+ led 314H;

[0080] 9) 13.6V Power LED 314I;

[0081] 10) 12V Repair LED 314J;

[0082] 11) 12V Cold / AGM LED 314K;

[0083] 12) 12V Standard LED 314L;

[0084] 13) Mode Button 314M; and

[0085] 14) Error LED 314N. ​

[0086] One or more temperature sensors and compensation

[0087] The battery charging device 310 is equipped with one or more temperature sensors (e.g., an ambient temperature sensor), such as Figure 3 As shown. For example, the battery charging device 310 is equipped with a single ambient temperature sensor or multiple ambient temperature sensors.

[0088] The A / C charging cable assembly 318 includes a wire with an A / C plug 322 at one end and an inlet plug 320 at the opposite end. The A / C plug 322 is detachably connected to a wall socket (e.g., a standard wall socket), and the inlet plug 320 is detachably connected to an inlet port 316 of the battery charging device 310.

[0089] The A / C charging cable assembly 318 has a temperature sensor 344 on its wires, a temperature sensor 346 on its inlet plug 320, and / or a temperature sensor 364 on its A / C plug 322. For example, the temperature sensor 364 may be electrically insulated from the conductors of the plug 322 and / or thermally connected (e.g., using thermally conductive gel, adhesive, or other materials) such that the temperature sensor measures the temperature of the plug 322 and / or the temperature of the electrical outlet port to which the plug 322 is detachably connected during operation of the battery charging device 310.

[0090] Similarly, the battery charging device 310 has one or more temperature sensors 345. These temperature sensors 345 may be located within the battery charging device 310. For example, one of the temperature sensors 345 may include a temperature sensor located in a compartment housing internal electrical components, and / or one or more temperature sensors 345 located in a separate compartment of the housing or enclosure 312 isolated from the compartment housing the internal electrical components of the battery charging device 310. One or both compartments may be provided with one or more vents or ventilation openings that communicate with the environment located outside the housing or enclosure 312.

[0091] Alternatively, a portion of the thermal sensing head or temperature sensor 345 may be positioned relative to the exterior of the housing or enclosure, with internal wiring connected to internal electrical components, or the temperature sensor 345 may be positioned in a separate enclosure located externally and connected to the housing or enclosure 312. Alternatively, the temperature sensor 345 may be housed in or connected to a portion of the display 314.

[0092] The battery cable assembly 326 includes a battery cable (e.g., a combined positive and negative cable) that is provided with an outlet plug 328 at one end, and a male electrical connector 330 at an opposite end. The outlet plug 328 is removably connected to the outlet port 324 of the battery charging apparatus 310, and the male electrical connector is removably connected to a female electrical connector 334 of the battery cable assembly 332. The outlet plug 328 is provided with a temperature sensor 350, the battery cable is provided with a temperature sensor 352, and / or the male electrical connector 330 is provided with a temperature sensor 330.

[0093] The battery cable assembly 322 includes a battery cable (e.g., a combined positive and negative cable) that is provided with a female electrical connector 334 at one end, and a positive battery clamp 336 and a negative battery clamp 338 at an opposite end. The female electrical connector 334 is removably connected to the male electrical connector 330 of the battery cable assembly 326, and the positive battery clamp 336 is removably connected to a positive battery terminal of a battery that has been discharged or depleted, and the negative battery clamp 338 is removably connected to a negative battery terminal of a battery that has been discharged or depleted.

[0094] The female electrical connector 334 is provided with a temperature sensor 356, the battery cable is provided with a temperature sensor 358, the positive battery clamp 336 is provided with a temperature sensor 360, and / or the negative battery clamp 338 is provided with a temperature sensor 362.

[0095] The battery charging apparatus 310 can have a single temperature sensor, multiple temperature sensors, and / or an entire set of temperature sensors, as shown in Figure 3 The temperature sensors can be wired (e.g., using one or more additional third electrically insulating wires) connected to internal electronics of the battery charging apparatus 310, and / or the temperature sensors can be wirelessly connected (e.g., using one or more wireless links).

[0096] The one or more temperature sensors are electrically connected to internal electronics of the battery charging apparatus 310, for example. For example, the one or more temperature sensors are electrically connected to a microcontroller of the battery charging apparatus 310.

[0097] The battery charging apparatus 310 (e.g., the microcontroller) can be configured to receive a single input and / or multiple inputs from the one or more temperature sensors. For example, the one or more temperature sensors sense an ambient temperature of an environment in which the battery charging apparatus 310 operates.

[0098] The battery charging device 310 (e.g., microcontroller) can be configured to selectively detect one or more signals from one or more temperature sensors. This allows the battery charging device 310 to determine the temperature of each temperature sensor and determine a temperature difference between two or more temperature sensors, thereby controlling or providing compensation to the operation of the battery charging device 310. For example, detecting an elevated temperature in a compartment housing internal electronics from an internal temperature sensor to control one or more aspects or functions of the battery charging device 310, and detecting an ambient temperature from an ambient temperature sensor to control one or more same or different aspects or functions of the battery charging device 310. The determined temperature difference of the internal temperature and the ambient temperature can control the same or different aspects or functions of the battery charging device.

[0099] For example, an internal temperature above a threshold temperature automatically shuts down the operation of the battery charging device 310. For example, an increased temperature difference slows the charging of the battery charging device 310 to a discharged or depleted battery. For example, a temperature above a threshold temperature of a discharged or depleted battery shuts down the operation of the battery charging device 310. For example, a temperature difference of a sensor located between the battery charging device and the discharged or depleted battery variably controls the charging rate (e.g., variably controls the voltage and / or current) of the battery charging device 310.

[0100] The battery charging device 310 (e.g., microcontroller) can be configured to receive one or more signals from the one or more temperature sensors in real-time (e.g., during a charging operation of the battery charging device 310). Alternatively, the one or more signals can be sampled at different times and / or at specific operating states of the battery charging device 310 and / or states of the discharged or depleted battery.

[0101] Force Mode Feature

[0102] A special charging mode feature and method, referred to as “Force Mode,” allows the user to force the charger to start charging even if the battery voltage is close to 0V. This allows the charger to be used to charge severely discharged lead-acid batteries, as well as recover over-discharged lithium batteries with an open BMS.

[0103] Force Mode operates as the normal charging mode, except that it is limited to a short period of time for safety reasons. The timeout period for Force Mode can be 5 minutes, or it can be longer or shorter, depending on the application, type, and size of the battery being charged.

[0104] After Force Mode terminates due to the specified Force Mode time expiring, the charger will check the battery voltage. If the battery voltage is above the normal start voltage threshold, the charger will start charging in its normal mode. If the battery voltage is still too low, the charger will return to its standby or shutdown mode.

[0105] Because the Force Mode operates without normal low battery voltage checks, the user interface will need to explicitly select the mode and provide user feedback that it is in that mode.

[0106] For example, the Force Mode feature and method can be applied to the battery charger 310. For example, the display 314 can be provided with an LED 314A Figure 1 ) to indicate when the Force Mode feature is "on". The battery charger 310 can be configured to automatically "turn on" and "turn off" the Force Mode feature, for example, the Force Mode feature is automatically turned on when the battery charger 310 is properly connected to a deeply discharged battery and the battery charger 310 is "turned on". Alternatively, the battery charger 310 can be provided with a switch (e.g., a button on the display 314) to manually "turn on" and "turn off" the Force Mode feature.

[0107] Figure 7 A flow chart of an exemplary Force Mode for initial charging of a deeply discharged battery is shown in FIG. 3. The flow chart shows:

[0108] Start 310 - Force Mode initially in Standby Mode.

[0109] Determination 312 - Mode button pressed for 5 seconds (seconds) and battery voltage is less than 1 V (volt). Detect deeply discharged battery voltage to determine if less than 1 V.

[0110] If "Yes", proceed to process 314 - All Mode LEDs blink.

[0111] If "No", return to "Start" 310.

[0112] Process 314 - All Mode LEDs blink (Mode Selection).

[0113] Determination 316 - Mode selected?

[0114] If "Yes", proceed to decision 318 - Clip opposite connection?

[0115] If "No", return to previous decision 316.

[0116] Decision 318 - Clip opposite connection?

[0117] If "Yes", proceed to process 320 - Reverse polarity LED on.

[0118] If "No", proceed to decision 322 - Battery voltage greater than protection voltage?

[0119] Process 320 - Reverse polarity LED on

[0120] Determination 322 - Battery voltage greater than protection voltage?

[0121] If YES, proceed to process 326 - High voltage LED on.

[0122] If NO, proceed to process 330 - Force mode start and live voltage at the clip (even if the clip is unplugged) and fuel gauge LED tracking and timeout (last) for 5 minutes.

[0123] Determination 324 - (Battery) Clip unplugged?

[0124] If YES, return to start 310.

[0125] If NO, return to previous decision 324.

[0126] Process 326 - High voltage LED on

[0127] Determination 328 - OVP condition exceeded?

[0128] If YES, return to start 310.

[0129] If NO, return to previous decision 328.

[0130] Process 330 - Force mode start and live voltage at the clip (even if the clip is unplugged) and fuel gauge LED tracking and timeout for 5 minutes.

[0131] Figure 6 and Figure 7 Another battery charging device 110 according to the present application is shown in FIG. 3.

[0132] The battery charging device 110 includes a housing or case 112 that houses the electronic components of the battery charging device 110, an electronic display 114 (i.e., a graphical user interface (GUI)), a positive battery cable 116 with a positive battery clip 118 Figure 2 , and a negative battery cable 120 with a negative battery clip 122 Figure 2 .

[0133] Figure 3A functional block diagram of a battery charging device (e.g., a hand-held battery voltage regulator) according to an aspect of the present application is shown. At the center of the hand-held battery voltage regulator is a lithium polymer battery pack 32 that stores enough energy to jump-start the engine of a vehicle serviced by a conventional 12-volt lead-acid or valve-regulated lead-acid battery. In one exemplary embodiment, the high-inrush 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).

[0134] A programmable microcontroller unit (MCU) 1 receives various inputs and generates information as well as control outputs. The programmable MCU 1 also provides flexibility to the system by allowing functional and system parameter updates without requiring any changes to the hardware. According to one example embodiment, an 8-bit microcontroller with 2K x 15-bit flash memory is used to control the system. One such microcontroller is the HT67F30, which is commercially available from Holtek Semiconductor Inc.

[0135] When the hand-held battery voltage regulator device is connected to the electrical system of a vehicle, a car battery reverse sensor 10 monitors the polarity of the vehicle battery 72. As described below, the voltage regulator device prevents the lithium battery pack from being connected to the vehicle battery 72 when the terminals of the battery 72 are connected to the wrong terminals of the voltage regulator device. A car battery isolation sensor 12 detects whether the vehicle battery 72 is connected to the voltage regulator device and prevents the lithium battery pack from being connected to the output terminals of the voltage regulator device unless a good (e.g., chargeable) battery is connected to the output terminals.

[0136] The smart switch FET circuit 15 only switches the hand-held battery voltage regulator lithium battery to the electrical system of the vehicle when the vehicle battery is determined by the MCU 1 to be present (in response to a detection signal provided by the isolation sensor 12) and connected in the correct polarity (in response to a detection signal provided by the reverse sensor 10). A lithium battery temperature sensor 20 monitors the temperature of the lithium battery pack 32 to detect overheating due to high ambient temperature conditions and excessive current draw during jump-starting. A lithium battery voltage measurement circuit 24 monitors the voltage of the lithium battery pack 32 to prevent the voltage potential from rising too high during a charging operation and from falling too low during a discharging operation.

[0137] The lithium battery reverse charge protection diode 28 prevents any charging current delivered to the vehicle battery 72 from flowing back to the lithium battery pack 32 from the vehicle's electrical system. A flashlight LED circuit 36 is provided to provide a flashlight function for enhanced light under the hood of the vehicle in dark conditions, as well as to provide SOS and strobe light functions for safety purposes when the vehicle can be disabled in a potentially dangerous location. A voltage regulator 42 provides regulation of the internal operating voltage for the microcontroller and sensors. An on / off manual mode and flashlight switch 46 allows the user to control the energization of the hand-held battery voltage regulator device, thereby controlling the manual override operation in the event the vehicle has no battery, as well as controlling the flashlight function. The manual button only functions when the voltage regulator device is energized. This button allows the user to jump start a vehicle that has a missing or low battery voltage that cannot be detected automatically by the MCU. When the user presses the manual override button and holds it for a predetermined period of time, for example three seconds, to prevent accidental activation of the manual mode, the internal lithium ion battery power is switched to the vehicle battery connection port. The only exception to the manual override is the case of a reverse connection of the vehicle battery. If the vehicle battery is connected in reverse, the internal lithium battery power will never be switched to the vehicle battery connection port.

[0138] The USB charging circuit 52 converts power from any USB charger source to a charging voltage and current for charging the lithium battery pack 32. The USB output 56 provides a USB portable charger for charging smart phones, tablets and other rechargeable electronic devices. The operating indicator LED 60 provides a visual indication of the lithium battery capacity status as well as an indication of the smart switch activation status (indication power is being provided to the vehicle's electrical system). The detailed operation of the hand-held voltage regulator device will now be described with reference to the schematic diagrams of Figures 2A-2C. As Figure 2 A to the schematic diagrams of Figures 2A-2C. As Figure 2As shown in FIG. 1, the microcontroller unit 1 is the center of all inputs and outputs. The reverse battery sensor 10 includes a photo coupler isolator phototransistor (4N27) connected to the terminals of the vehicle battery 72 at input pins 1 and 2 through diode D8 in the lead conductor associated with the negative terminal CB- of pin 1, such that if the battery 72 is connected to the terminals of the voltage regulating device with the correct polarity, the photo coupler LED 11 will not conduct current. It is therefore turned off, providing a "1" or high output signal to the MCU 1. The car battery isolation sensor 12 includes a photo coupler isolator phototransistor (4N27) connected to the terminals of the vehicle battery 72 at input pins 1 and 2 through diode D7 in the lead conductor associated with the positive terminal CB+ of pin 1, such that if the battery 72 is connected to the terminals of the voltage regulator device with the correct polarity, the photo coupler LED 11A will conduct current. It is therefore turned on, providing a "0" or low output signal to the MCU, indicating that a battery is present across the jumper output terminals of the hand-held voltage regulating device.

[0139] If the car battery 72 is connected to the hand-held voltage regulating device with the opposite polarity, the photo coupler LED 11 of the reverse sensor 10 will conduct current, providing a "0" or low signal to the microcontroller unit 1. Additionally, if no battery is connected to the hand-held voltage regulator device, the photo coupler LED 11A of the isolation sensor 12 will not conduct current and is therefore turned off, providing a "1" or high output signal to the MCU, indicating that no battery is connected to the hand-held voltage regulator device. Using these specific inputs, the microcontroller software of the MCU 1 can determine when it is safe to turn on the smart switch FET 15, connecting the lithium battery pack to the jumper terminals of the voltage regulating device. Therefore, if the car battery 72 is not connected to the voltage regulating device at all, or is connected with the opposite polarity, the MCU 1 can prevent the smart switch FET 15 from being turned on, preventing a short circuit of the lithium battery pack.

[0140] As Figure 2The FET smart switch 15 shown in B is driven by the microcontroller 1 output. The FET smart switch 15 includes three FETs (Q15, Q18, and Q19) in parallel that spread the power distribution from the lithium battery pack to the FETs. When this microcontroller output is driven to a logic low, the FETs 16 are all in a high resistance state, thus not allowing current to flow from the internal lithium battery negative contact 17 to the car battery 72 negative contact. When the microcontroller output is driven to a logic high, the FETs 16 (Q15, Q18, and Q19) are in a low resistance state, thus allowing current to freely flow from the internal lithium battery pack negative contact 17 (LB-) to the car battery 72 negative contact (CB-). In this way, the microcontroller software controls the connection of the internal lithium battery pack 32 to the vehicle battery 72 to jump start the car engine. Referring back to Figure 2 A, one of the circuit 24 and the microcontroller 1 analog inputs can be used to accurately measure the internal lithium battery voltage. The circuit 24 is designed to sense when the main 3.3V regulator 42 voltage is on, and to turn on the transistor 23 when the regulator 42 voltage is on. When the transistor 23 is on, it turns on the FET 22, thus providing a conductive path to the voltage divider 21 for the internal lithium battery positive contact (LB+), thus allowing the lower voltage range to be brought to the microcontroller to be read. Using this input, the microcontroller software can determine if the lithium battery voltage is too low during a discharge operation or too high during a charge operation, and take appropriate action to prevent damage to the electronics.

[0141] Still referring to Figure 2 A, the temperature of the internal lithium battery pack 32 can be accurately measured by two negative temperature coefficient (NTC) devices 20. These negative temperature coefficient (NTC) devices 20 are devices that have a decreasing resistance as the temperature increases. This circuit is a voltage divider that brings the result to two analog to digital (A / D) inputs on the microcontroller 1. The microcontroller software can then determine when the internal lithium battery is overheating and not allowing jump starting, thus adding a level of safety to the design.

[0142] The main voltage regulator circuit 42 is designed to convert the internal lithium battery voltage to a regulated 3.3 volts that is used by the microcontroller 1 as well as other components of the voltage regulation device for internal operating power. Three lithium battery reverse charge protection diodes 28 (see Figure 2 B) are in place to allow current to flow only from the internal lithium battery pack 32 to the car battery 72, and not from the car battery to the internal lithium battery. In this way, if the car electrical system is charging from its alternator, the car electrical system cannot back charge the internal lithium battery (thus damaging the internal lithium battery), thus providing another level of safety. The main power supply on switch 46 ( Figure 2A) is a combination that allows for double pole double throw operation, so that by one push, the product can start if it is in the off state, or the product can turn off if it is in the on state. This circuit also uses microcontroller output 47 to "keep alive" the power supply when it is activated by the power on switch. When the switch is pressed, the microcontroller switches this output to a high logic level, keeping the power on when the switch is released. In this way, the microcontroller keeps control of when the power is turned off when the on / off switch is activated again or when the lithium battery voltage becomes too low. This microcontroller software also includes a timer that turns off the power after a predetermined period of time (e.g. 8 hours) if not used. Figure 2 The torch LED circuit 45 shown in B controls the operation of the torch LEDs. Two outputs from the microcontroller 1 are dedicated to two separate LEDs. Thus, the LEDs can be independently software controlled for the strobe and SOS modes, providing another safety feature for the voltage regulation device. The LED indicators provide feedback to the operator of what is happening with the product. Four separate LEDs 61 Figure 2 A) are controlled by respective separate outputs of the microcontroller 1 to provide an indication of the remaining charge of the internal lithium battery. These LEDs are controlled in a "fuel gauge" type format with 25%, 50%, 75% and 100% (red, red, yellow, green) charge indications. When the vehicle battery 72 is connected with the opposite polarity, the LED indicators 63 Figure 2 B) provide visual warnings to the user. The "regulated" and on / off LEDs 62 provide visual indications when the voltage regulation device is providing jump start power and when the voltage regulation device is on, respectively.

[0143] The USB output 56 circuit Figure 2 C) to provide a USB output for charging a portable electronic device such as a smart phone from the internal lithium battery pack 32. Control circuitry 57 from the microcontroller 1 allows the USB Out 56 to be turned on and off by software control to prevent the internal lithium battery from becoming too low. The USB output is brought to the outside of the device on a standard USB connector 58 that includes the standard voltage divider required to allow charging of some smart phones that require it. The USB charging circuit 52 allows the internal lithium battery pack 32 to be charged using a standard USB charger. This charging input uses a standard micro USB connector 48 that allows the use of a standard cable. A DC-DC converter 49 is used to up-convert the 5V potential provided by a standard USB charger to the 12.4V DC voltage required to charge the internal lithium battery pack. The DC-DC converter 49 can be turned on and off by an output from the microcontroller 1 via circuit 53.

[0144] In this way, if the A / D input 22 measures that the battery voltage is too high, the microcontroller software can shut off charging. Additional safety is provided to help eliminate overcharging of the internal lithium battery using the lithium battery charge controller 50 that provides charge balancing to the internal lithium battery cells 51. This controller also provides safety redundancy for eliminating over-discharge of the internal lithium battery.

[0145] Figure 5 A hand-held device 110 according to an exemplary embodiment of the present application is shown. 112 is the housing. 114 is the display. 114A is the power-on switch. 114B is the LED "fuel gauge" indicator. 114C is the "regulated" indicator for showing that power is being provided to the 12V outlet port 122. 114D is the "reverse" indicator for showing that the vehicle battery is connected with the polarity incorrect. 114E is a "powered on" indicator for showing that the device is powered on for operation. 118 is the USB input port for charging the internal lithium-ion battery. 118A is the removable cover for the USB input port 118. 120 is the USB output port for providing power from the internal lithium-ion battery to other portable devices such as smart phones, tablets, music players and other electronic devices. 120A is the removable cover for the USB output port 120. 122 is the 12V outlet port that can be connected to the jumper cable device 210 described below.

[0146] Figure 6 A jumper cable device 210 is shown that is specifically designed for use with the hand-held device 110. The device 210 has a plug 212 that is configured to be inserted into the 12V outlet port 122 of the hand-held device 110. The positive battery cable 214 and the negative battery cable 218 are integrated with the plug 212 and are connected to the positive battery clamp 216 and the negative battery clamp 220 through ring connectors 216A and 220A, respectively. The 12V outlet port 122 and the plug 212 are sized so that the plug 212 will only fit into the 12V outlet port 122 in a specific orientation, thereby ensuring that the positive battery clamp 216 will correspond to the positive polarity and the negative battery clamp 220 will correspond to the negative polarity, as shown above.

[0147] In addition, the ring terminals 216A and 216B allow the battery clamps 216 and 229 to be disconnected from the battery cables 214 and 218 and then be removably connected directly to the terminals of the vehicle battery. This feature can be used, for example, to permanently connect the battery cables 214 and 218 to the vehicle's battery. In the event that the battery voltage becomes depleted or discharged, the hand-held regulated voltage device 110 can be very simply and correctly connected to the depleted or discharged vehicle battery by inserting the plug 212 into the 12V outlet port 122.

[0148] Having thus described the application with the detail to enable those skilled in the art to make and use it, it will be obvious that various changes can be made without departing from the spirit or scope of the application. Any and all such changes are intended to be included within the scope of the following claims.

Claims

1. A battery charging apparatus for charging a discharged or depleted battery, the battery charging apparatus comprising: one or more ambient temperature sensors for measuring a temperature external to the battery charging apparatus; an internal temperature sensor for measuring an internal temperature of the battery charging apparatus; and a controller receiving input signals from the one or more ambient temperature sensors for compensating for charging operations of the battery charging apparatus, wherein the one or more ambient temperature sensors include a first temperature sensor located on a battery clamp configured to connect the battery charging apparatus to the discharged or depleted battery or on a battery cable assembly connected to the battery clamp, and wherein the first temperature sensor is positioned to detect a temperature of the discharged or depleted battery when the discharged or depleted battery is connected to the battery clamp, and wherein the controller receives input signals from the one or more ambient temperature sensors and from the internal temperature sensor and variably controls a charging rate of the discharged or depleted battery while actively charging the discharged or depleted battery based on both the temperature of the one or more ambient temperature sensors and the temperature of the internal temperature sensor. The one or more ambient temperature sensors include a second temperature sensor to detect a temperature of an environment in which the battery charging apparatus operates.

2. The battery charging apparatus according to claim 1, wherein The first temperature sensor is located on the battery clamp.

3. The battery charging apparatus according to claim 1, wherein, The second temperature sensor is connected to or associated with a housing or casing of the battery charging apparatus.

4. The battery charging apparatus according to claim 2, wherein The one or more ambient temperature sensors include a temperature sensor connected to or associated with a battery cable assembly of the battery charging apparatus.

5. The battery charging apparatus of claim 1, wherein, The controller variably controls the charging rate of the discharged or depleted battery based on one or more temperature differentials of the one or more ambient temperature sensors and the internal temperature sensor.

6. The battery charging apparatus of claim 1, wherein, 7. The battery charging apparatus of claim 6, further comprising: a rechargeable battery having a positive terminal and a negative terminal; a positive battery cable connected to or connectable to the positive terminal of the rechargeable battery; a negative battery cable connected to or connectable to the negative terminal of the rechargeable battery; a detector for measuring an output voltage of a deeply discharged battery; a programmable microcontroller unit connected to one or more components or parts of the rechargeable battery charging apparatus, the programmable microcontroller unit being structured and arranged to control operation of the rechargeable battery charging apparatus; and a user interface connected to the programmable microcontroller unit, the user interface being structured and arranged to display one or more functions or modes of the rechargeable battery charging apparatus; wherein the controller is structured and arranged to control charging of the deeply discharged battery, the controller having a force mode for charging the deeply discharged battery even if the battery voltage approaches 0 volts. The force mode is configured to operate for a predetermined period of time.

8. The battery charging apparatus of claim 7, wherein, The predetermined period of time is 5 minutes.

9. The battery charging apparatus of claim 8, wherein, ​ 10. The battery charging apparatus of claim 8, wherein, After the forced mode terminates due to the expiration of the predetermined time period, the rechargeable battery charging device will measure the voltage of the deeply discharged battery.

11. The battery charging apparatus of claim 10, wherein, If the deeply discharged battery is above a normal start voltage threshold, the rechargeable battery charging device will begin charging in a normal mode.

12. The battery charging apparatus of claim 11, wherein, If the deeply discharged battery voltage is too low, the rechargeable battery charging device will return to a standby mode or a shut down mode.

13. The battery charging apparatus of claim 7, wherein, The user interface is configured and arranged to allow a user to select the forced mode.

14. The battery charging apparatus of claim 13, wherein, The user interface is configured to provide user feedback if the rechargeable battery charging device is in the forced mode.

15. The battery charging apparatus of claim 14, wherein, The user feedback is provided by illuminating a light emitting diode.

16. The battery charging apparatus of claim 9, wherein, The deeply discharged battery is a lead acid battery.

17. The battery charging apparatus of claim 9, wherein, The deeply discharged battery is an over-discharged lithium ion battery with an open battery management system.

18. The battery charging apparatus of any one of claims 6 to 17, wherein, An increased temperature difference causes the controller to slow the charging of the discharged or depleted battery.

19. A method of charging a discharged or depleted battery using a battery charging device, the method comprising: detecting an ambient temperature external to the battery charging device using a temperature sensor, the temperature sensor being located on a battery clamp configured to connect the battery charging device to the discharged or depleted battery or on a battery cable assembly connected to the battery clamp, wherein the temperature sensor is positioned to detect a temperature of the discharged or depleted battery when the discharged or depleted battery is connected to the battery clamp; detecting an internal temperature of the battery charging device using an internal temperature sensor within the battery charging device; and compensating for charging operations of the battery charging device based on the detected ambient temperature and the detected internal temperature, including variably controlling a charging rate of the discharged or depleted battery while actively charging the discharged or depleted battery based on both the ambient temperature and the internal temperature.

20. The method of claim 19, wherein, The charging rate of the discharged or depleted battery is based on a temperature difference of the ambient temperature and the internal temperature.

21. The method of claim 20, wherein, An increased temperature difference causes the charging rate to decrease.

22. The method of any one of claims 19-21, wherein, The ambient temperature is measured using a temperature sensor on the battery clamp.

23. The method of any one of claims 19-21, wherein, Terminating charging of the discharged or depleted battery upon detecting a temperature that exceeds a threshold temperature detected for the discharged or depleted battery.

24. The method of any one of claims 19-21, wherein, Not initiating charging of the discharged or depleted battery upon detecting a temperature that exceeds a threshold temperature detected for the discharged or depleted battery.

25. The method of any one of claims 19-21, wherein, The battery charging device measures a temperature of the battery charging device prior to charging operations of the battery charging device.

26. The method of any one of claims 19-21, wherein, The battery charging device measures a temperature of the discharged or depleted battery prior to charging operations of the battery charging device.

Images