Automated d-cell lithium thionyl chloride battery depassivation and state-of-health testing apparatus

Abstract

A battery health and depassivation testing apparatus includes a timed switch electrically connected to the positive terminal of the battery and a timer circuit to control the timed switch while conducting the battery test, a test initiation switch and a test-in-progress indicator. During the test the battery is connected to a current sink circuit to establish a load condition for a predefined period of time. A comparator is used to test the battery's voltage to a known DC voltage following the load condition. Pass / fail indicator LEDs are provided to display the results of the test. The battery health and depassivation testing apparatus also includes a polarity protection circuit connected to a polarity error indicator to prevent damage to the circuitry due to the battery being installed backwards.

Description

Attorney Docket No. 34704.2500 (940-0188-AT WO01)AUTOMATED D-CELL LITHIUM THIONYL CHLORIDE BATTERY DEPASSIVATION AND STATE-OF-HEALTH TESTING APPARATUSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U. S. Provisional Application No.63 / 736,790, filed December 20, 2024, the entire contents of which is incorporated by reference in its entirety.FIELD

[0002] The present disclosure relates to an apparatus and method of battery depassivation. More particularly, the present disclosure related to an apparatus and method for battery depassivation and testing under load to ensure battery operability for an intended use.BACKGROUND

[0003] Storage of Lithium Thionyl Chloride (LTC) batteries presents an issue due to battery passivation. Passivation is a chemical process that creates a protective layer on a material, for example, on the anodes and cathodes of a battery cells. The buildup of a passivation layer tends to disrupt current flow from the battery. From an electrical perspective, a passivation layer essentially looks like a large series resistance on the cell. This results in a voltage drop when current is drawn from the battery, making the battery appear to have a lower voltage than its actual voltage.

[0004] Passivation occurs over time, beginning as soon as a charged battery ceases to deliver current. The rate of passivation is influenced by its environment. For example, storage at higher temperatures accelerates the passivation process. Generally, high levels of current can remove or reduce the passivation from the battery cell. However,after long periods of storage some of the passivation iayer cannot be removed, permanently altering the ability of the battery to provide the needed current in a circuit.

[0005] The buildup of a passivation layer essentially shortens the expected lifetime of a battery. Passivation can also potentially cause errors in the circuitry that depends on the battery voltage to remain stable. Batteries with a passivation layer that cannot be removed must be discarded. It can take considerable effort to determine which batteries, if any, have passivation damage to the point where they are no longer suitable for use.SUMMARY

[0006] Various examples of the present disclosure can overcome the afore-mentioned disadvantages and other drawbacks associated with the buildup of passivation layers on LTC batteries, and offers new advantages as well.

[0007] According to various examples of the present disclosure there is provided an automated D-cell Lithium Thionyl Chloride (LTC) battery depassivation and state-of-health testing apparatus that includes a pair of removable electrodes including a first removable electrode configured to detachably connect to a first battery terminal of the battery, and second removable electrode configured to detachably connect to a second battery terminal of the battery. Various examples of the apparatus also include a polarity protection circuit electrically connected to one electrode of the pair of removable electrodes, and a polarity error indicator including a first lead electrically connected to the first removable electrode and a second lead electrically connected to the second removable electrode. Various examples of the apparatus also include a test initiation switch with an initiate output terminal and a reset output terminal, and a timer circuit with a timer input terminal and a timer output terminal, the timer input terminal being electrically connected to the initiate output terminal of the test initiation switch. Various examples of the apparatus also include a test-in-progress indicator electrically connected to the timer output terminal of the timer circuit, a current sink circuit electrically connected to the first removable electrode, and a DC power supply. Various examples of the apparatus also include a comparator circuit including a first comparator input electrically connected to the first removable electrode to provide the battery voltage to the comparator circuit, the comparator circuit including a second comparatorinput electrically connected to the DC power supply, and an indicator drive circuit electrically connected to the comparator circuit.

[0008] In some forms, the first battery terminal is a cathode and the second battery terminal is an anode, and the apparatus further includes a pass indicator electrically connected to the indicator drive circuit.

[0009] In some forms, the polarity protection circuit is electrically connected to the cathode of the battery via the first removable electrode, and the apparatus further includes a fail indicator electrically connected to the indicator drive circuit.

[0010] In some forms, the polarity error indicator includes an LED and a resistor, and the DC power supply is a 5.0 volt DC power supply.

[0011] In some forms, the current sink circuit is electrically connected by a controllable electrical connection to the cathode of the battery via the polarity protection circuit and the first removable electrode, and the timer circuit maintains the controllable electrical connection between the cathode of the battery and the current sink circuit for a predefined period of time.

[0012] In some forms, the first comparator input of the comparator circuit is electrically connected to the cathode of the battery via the polarity protection circuit and the first removable electrode, and the second comparator input is electrically connected to the DC power supply via a voltage terminal of a voltage divider, and the voltage terminal is maintained at a nominal test voltage for the battery.

[0013] In some forms, the comparator circuit outputs a pass output if the battery voltage is equal to or greater than the nominal test voltage, and the comparator circuit outputs a fail output if the battery voltage is less than the nominal test voltage.

[0014] In some forms, the indicator drive circuit is electrically connected to the comparator circuit.

[0015] In some forms, the timed switch is electrically connected to the cathode of the battery via the polarity protection circuit and the first removable electrode.

[0016] In some forms, the timer circuit is electrically connected to the current sink circuit.

[0017] In some forms, the predefined period of time is 75 seconds + / - 60 seconds. In some forms, the predefined period of time is 30 + / - 10 seconds.

[0018] In some forms, a health and depassivation testing circuitry apparatus for a battery characterized by a battery voltage includes a pair of removable electrodes including a first removable electrode configured to detachably connect to a first battery terminal of the battery, and second removable electrode configured to detachably connect to a second battery terminal of the battery, a P-channel MOSFET transistor including a source terminal, a gate terminal electrically connected to the second removable electrode, and a drain terminal electrically connected to the second removable electrode, a DC power supply, a first LED including a first LED cathode terminal electrically connected to the first removable electrode and including a second LED anode terminal electrically connected to the second removable electrode via a first resistor, wherein the first LED is configured to indicate a polarity error, a test initiation switch with an initiate output terminal and a reset output terminal, a timer integrated circuit with a timer input terminal and a timer output terminal, the timer input terminal being electrically connected to the initiate output terminal of the test initiation switch, a second LED in series with a second resistor, the second LED including a second anode terminal controlled by the timer integrated circuit, and including a second cathode electrically connected to ground, wherein the second LED is configured to indicate testin-progress, a current sink circuit including a resistor electrically connected to the source terminal of the P-channel MOSFET transistor, a comparator circuit including a comparator output terminal, a first comparator input terminal electrically connected to the first removable electrode to provide the battery voltage to the comparator circuit, and a second comparator input terminal electrically connected to the DC power supply, an indicator drive circuit including an indicator drive input electrically connected to the comparator output.

[0019] In some forms, the first battery terminal is a cathode and the second battery terminal is an anode, and the includes a third LED electrically connected to an indicator drive output of the indicator drive circuit.

[0020] In some forms, the polarity protection circuit is electrically connected to the cathode of the battery via the first removable electrode, and the apparatus further includes a fail indicator electrically connected to the indicator drive circuit.

[0021] According to various examples of the present disclosure there is provided an automated D-cell Lithium Thionyl Chloride (LTC) battery depassivation and state-of-health testing apparatus that includes a pair of electrodes including a first electrode configured to detachably connect to a cathode of the battery, and second electrode configured to detachably connect to an anode of the battery. Various examples of the apparatus also include a polarity protection circuit electrically connected to one electrode of the pair of electrodes, and a polarity error indicator including a first lead electrically connected to the first electrode and a second lead electrically connected to the second electrode. Various examples of the apparatus also include a test initiation switch with an initiate output terminal and a reset output terminal, and a timer circuit with a timer input terminal and a timer output terminal, the timer input terminal being electrically connected to the initiate output terminal of the test initiation switch. Various examples of the apparatus also include a test-in-progress indicator electrically connected to the timer output terminal of the timer circuit, a current sink circuit electrically connected to the first electrode, and a DC power supply. Various examples of the apparatus also include a comparator circuit including a first comparator input electrically connected to the first electrode to provide the battery voltage to the comparator circuit, the comparator circuit including a second comparator input electrically connected to the DC power supply, and an indicator drive circuit electrically connected to the comparator circuit.

[0022] According to various examples of the present disclosure there is provided an automated D-cell Lithium Thionyl Chloride (LTC) battery depassivation and state-of-health testing apparatus that includes a pair of electrodes including a first electrode configured to detachably connect to a cathode of the battery, and second electrode configured to detachably connect to an anode of the battery. Various examples of the apparatus also include a polarity error indicator including a first lead electrically connected to the first electrode and a second lead electrically connected to the second electrode. Various examples of the apparatus also include a test initiation switch with an initiate output terminal and a reset output terminal, and a timer circuit with a timer input terminal and a timer output terminal, the timer input terminal being electrically connected to the initiate output terminal of the test initiation switch. Various examplesof the apparatus also include a test-in-progress indicator electrically connected to the timer output terminal of the timer circuit, and a DC power supply. Various examples of the apparatus also include a comparator circuit including a first comparator input electrically connected to the first electrode to provide the battery voltage to the comparator circuit, the comparator circuit including a second comparator input electrically connected to the DC power supply, and an indicator drive circuit electrically connected to the comparator circuit.

[0023] The disclosure herein should become evident to a person of ordinary skill in the art given the following enabling description and drawings. The drawings are for illustration purposes only and are not drawn to scale unless otherwise indicated. The drawings are not intended to limit the scope of the disclosure. The following enabling disclosure is directed to one of ordinary skill in the art and presupposes that those aspects within the ability of the ordinarily skilled artisan are understood and appreciated.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Various aspects and advantageous features of the present disclosure will become more apparent to those of ordinary skill when described in the detailed description of preferred examples and reference to the accompany drawing wherein:

[0025] FIG. 1 depicts a block diagram of an LTC battery health and depassivation testing apparatus according to various examples disclosed herein.

[0026] FIG. 2 depicts a circuit diagram of an LTC battery health and depassivation testing apparatus according to various examples disclosed herein.

[0027] FIG. 3A depicts circuit diagrams of portions of an LTC battery health and depassivation testing apparatus according to various examples disclosed herein.

[0028] FIG. 3B depicts circuit diagrams of portions of an LTC battery health and depassivation testing apparatus according to various examples disclosed herein.DETAILED DESCRIPTIONS

[0029] FIG. 1 depicts a block diagram of an LTC battery health and depassivation testing apparatus 100 according to various examples disclosed herein. The battery testing apparatus 100 includes a polarity protection circuit 103, a polarity error indicator105, a test initiation switch 107, a timer circuit 109, a test-in-progress indicator 111, a timed switch circuit 113, current sink circuitry 115, a comparator circuit 117, a DC power supply 119, indicator drive circuitry 121, a test pass indicator 123 and a test fail indicator 125. The various components of the battery testing apparatus 100 may be interconnected in the manner displayed in FIG. 1.

[0030] The electrodes 127a-b (e.g., removable electrodes) are configured to be removably attached to the terminals of the battery 101 that is under test. The removable electrodes 127a-b are constructed from a conductive— i.e., metal— material, and may take the form of clips that attach to the terminals, spring loaded electrodes, or other such mechanical connector configurations for making electrical contact known to those of ordinary skill in the art. In FIG. 1 removable electrode 127a attaches to the cathode (+ terminal) of battery 101, and removable electrode 127b attaches to the anode (- terminal) of battery.

[0031] A polarity protection circuit 103 is provided to prevent damage to the apparatus due to the battery 101 being inserted backwards. If the battery 101 is inserted backwards, an open circuit isolates the voltage of the battery from the circuitry of apparatus 100, and activates a polarity error indicator 105. The polarity error indicator 105 is typically an LED located near the battery 101 insertion point with a label indicating that the battery 101 is inserted improperly. However, other examples of the polarity error indicator 105 may provide a different type of indication (e.g., an auditory signal, a haptic signal, a signal sent via a wireless communication network, and / or a visual indicator using something other than an LED). With the battery 101 inserted properly, the apparatus is ready to begin testing the battery 101, awaiting an input from the user.

[0032] Once the battery 101 is properly connected to removable electrodes 127a-b the battery test can begin in response to the user manipulating the test initiation switch 107. The switch 107 may be a button switch, a toggle switch or other such mechanical structures for making electrical contact or otherwise sending an initiation signal or voltage. The test initiation switch 107 is typically mounted on the enclosure encompassing the circuitry and components of apparatus 100. In some examples the switch 107 may be located remotely with communication lines — either wired or wireless — to the enclosure. The test initiation switch 107 may, in some examples, be connected to multiple batterytesters 100 in order to test multipie batteries 101 in parallel. The test initiation switch 107 may be implemented in the form of a computer input device — e.g., a key on a keyboard, a mouse, and / or a touch screen — or a smartphone, and be connected via a wired and / or wireless connection to the circuity of the battery testing apparatus 100.

[0033] The test initiation switch 107 is connected to timer circuity 109 and indicator drive circuitry 121. In response to the user input, a reset signal from the test initiation switch 107 is sent to indicator drive circuitry 121, and an initiate signal from the test initiation switch 107 to the timer circuit 109 puts the apparatus 100 in a state to begin the battery testing.

[0034] The timer circuit 109 begins timing the operation, and a controllable switch in the current sink circuitry 115 provides a controllable electrical connection to put battery 101 in a load condition by electrically connecting the battery 101 s cathode at terminal 127a to ground via the current sink circuitry 115. At the same time the test-in-progress indicator 111 is lit up, for example, by a signal from the timer circuit 109. The battery 101 is maintained in a load condition with current sink circuit 115 drawing current from the battery 101 for a predefined period of time. In some examples current is drawn for 30 + / -10 seconds. In other examples timer circuit 109 may be configured to allow current to be drawn for a length of time of: no greater than 35 seconds; or 75 seconds + / - 60 seconds; or no greater than 1 minute; or no greater than 2 minutes; or no greater than 5 minutes, or no greater than 10 minutes.

[0035] Once the predefined period of time has passed — e.g., 30 + / - 10 seconds — the output from the timer circuit 109 controls the timed switch 113 to produce an open circuit, thus ceasing the load condition on battery 101. At this time the test-in-progress indicator 111 is turned off indicating that the testing is completed.

[0036] Putting the battery 101 under a load condition draws current from the battery and also tends to draw down the voltage somewhat. The voltage of battery 101 falling below a predefined voltage level is an indication that the battery 101 lacks a sufficient charge to be considered “good.” The battery testing apparatus 100 shown in FIG. 1 tests LTC batteries by comparing their output voltage to a predefined battery quality minimum threshold voltage (or simply, battery threshold voltage). For an LTC battery a battery quality minimum threshold voltage of 3.2 volts DC may be used, as shown in the figuresand discussed in the examples provided herein. However, depending upon the requirements of the client and intended usage of the battery, other values may be used as a battery quality minimum threshold voltage. For example, the battery quality minimum threshold voltage may be defined to be a value of at least 3.0 volts DC, or may be defined to be any value greater than 3.0 volts DC up to 3.6 volts DC, the nominal voltage of an LTC battery— e.g., 3.1 VDC, 3.3 VDC, 3.45 VDC, etc. The comparison of the battery 101 ’s voltage to the predefined battery quality minimum threshold voltage is done by comparator circuit 117. At the time the load condition is completed, timed switch 113 opens the electrical connection between the battery 10Ts output and the current sink circuitry 115, and provides an electrical connection from the battery 101 ’s output to the VBA T input of comparator circuit 117.

[0037] If the battery 101 ’s voltage at VBATT is equal or greater than 3.2 volts DC the signal on the output of the comparator 117 causes the indicator drive circuitry 121 to light up the pass indicator 123. However, if the VBATT input from battery 101 is less than 3.2 volts the output of the comparator 117 will cause the indicator drive circuitry 121 to light up the fail indicator 125. Once the test-in-progress indicator 111 is shut off, and one of the pass / f ail indicators 123 / 125 is lit, the testing of the battery is completed. FIG. 1 depicts a pass indicator 123 and a fail indicator 125. In some implementations the pass indicator 123 and fail indicator 125

[0038] FIG. 2 depicts a circuit diagram of an LTC battery health and depassivation testing apparatus according to an example for checking the health of a 3.2V LTC battery of the type commonly used in sensors or meters used in connection with overhead electric distribution infrastructure. As will be appreciated, in these applications products are typically equipped with long life batteries and may be warehoused for extended periods of time. The circuitry depicted in FIGS. 3A-B corresponds in function to the similarly labeled boxes in the block diagram of FIG. 1. The battery testing apparatus 100 may be configured to include removable electrodes 127a-b, a polarity protection circuit 103, a polarity error indicator 105, a test initiation switch 107, a timer circuit 109, a test-in¬ progress indicator 111, a timed switch circuit 113, current sink circuitry 115, a comparator circuit 117, a DC power supply 119, indicator drive circuitry 121, a test pass indicator 123 and a test fail indicator 125. The various components of the battery testing apparatus100 may be interconnected in the manner displayed in FIG. 2 while functioning in the manner described in conjunction with FIG. 1.

[0039] FIG. 3A depicts circuit diagrams of portions of an LTC battery health and depassivation testing apparatus (battery testing apparatus 100) according to various examples disclosed herein. The figure shows a battery 101 to be tested and circuitry of the battery testing apparatus 100. The battery testing apparatus 100 includes removable electrodes 127a and 127b that are removably attachable to the terminals of battery 101. The apparatus 100 includes a polarity error indicator 105 embodied as an LED labeled LED1 in the figure. However, a person of ordinary skill in the art would understand that the polarity error indicator 105 may be replaced with a different type of light emitter and / or any other type of device that can communicate information. LED1 is connected in series with a resistor R1 between the removable electrodes 127a-b. Resistor R1, at 200 ohms, prevents too much current from passing through LED1. The cathode of LED1 of polarity error indicator 105 is oriented towards removable electrode 127a which accepts the positive terminal of battery 101. In this way, if battery 101 is oriented wrong, current will flow through LED1, lighting the polarity error indicator 105. The polarity error indicator 105 may alternatively be implemented with other types of lights, a buzzer, or other indicators (e.g., a haptic signaling device, a device capable of sending signals via a wireless communication network, etc.).

[0040] The negative battery 101 electrode is connected to ground via removable electrodes 1 7b. The positive battery 101 electrode (i.e., the cathode) is connected to the polarity protection circuit 103 via removable electrodes 1 7a. In the implementation depicted in FIG. 3A the polarity protection circuit 103 comprises a P-channel MOSFET transistor with its gate connected to removable electrode 1 7b via a 100k resistor, its drain connected to the battery 101 cathode via removable electrode 127a, and its source connected to the current sink circuitry 115. If battery 101 is inserted incorrectly the P-channel MOSFET transistor turns off and no current will flow to circuitry connected to its source terminal. The polarity protection circuit 103 may alternatively be implemented with other types of transistors, relays or switches.

[0041] The polarity protection circuit 103 is connected to the current sink circuitry 115. The current sink circuitry 115 is controlled to turn on and off by the output of timer circuit109. The timer circuit 109 may implemented with a 555 timer IC. The timing and pulse width of the 555 timer IC can be altered to accommodate the desired length of time for the battery test. The switching circuitry in current sink circuitry 115 may be implemented with a general purpose NPN silicon transistors such as a MMBT2222 BJT chip. The transistors used as the current sink circuitry 115 switching circuitry are labeled Q2 and Q3 in FIG. 3A. The transistors Q2 and Q3, upon being turned on by the timer circuit 109 output, pulls 75 mA from the battery 101. The amount of current pulled from battery 101 may be adjusted by selecting size of resistors R4 and R5 and the Vcesat of the Q2 and Q3. The voltage drop across resistors R4 / R5 turns on transistor Q3 in response to current passing through transistor Q2.

[0042] A high signal from the output of timer circuit 109 turns on the current sink circuitry 115. The high output signal of timer circuit 109 depicted in FIG. 2 is approximately 5.0 volts since a 5.0 volt DC is powering the 555 timer IC. The high signal from the 555 timer IC to the base of to the Q2 transistor turns it on, passing current through the Q2 transistor to ground via parallel resistors R4 and R5 which are connected in parallel between the emitter of Q2 and ground. The voltage across the R4 / R5 resistor pair turns the Q3 transistor on, which in turn, drains excess current away from the base of transistor Q2. Since the resistance of R4 / R5 is low compared to the base impedance of Q3, most of the current passes through R4 and R5.

[0043] In the battery testing apparatus 100 the test initiation switch 107 may be implemented with a push button switch such as the KSC241 J. Pushing the test initiation switch 107 of FIG. 3A connects the TRIG input of the 555 timer IC of timer circuit 109 to ground, driving TRIG low. This triggers the 555 timer IC to begin timing the 30 second battery test. Pushing the test initiation switch 107 of FIG. 3A also allows current to flow from the 5.0 volt DC power supply 119, through resistors R7 and R8, to ground. In some forms, the DC power supply 119 may be a AC-DC converter that plugs into a wall outlet. The resistor R7 is connected between the collector and base of transistor Q4. The Q4 transistor may be implemented as a PMBT4403 bipolar junction transistor (BJT) transistor. The voltage across resistor R7 when current flows through it turns the Q4 transistor on, allowing current to flow to the flip-flop RESET input with indicator drive circuitry 121 (FF_RESET).

[0044] FIG. 3A depicts test-in-progress indicator 111 of the testing apparatus 100 which may be implemented with the LED labeled LED2. However, other examples of the test-in-progress indicator 111 may be another type of device (e.g., a visual signaling device other than an LED, an auditory signaling device, a haptic signaling device, a device capable of sending signals via a wireless communication network). In the figure the anode of the LED2 is connected in series with resistor R6 to a 5.0 VDC power supply. Resistor R6, a 200 ohm resistor, limits the current flowing through LED2 of test-inprogress indicator 111. The cathode of test-in-progress LED2 is connected to the collector of general purpose transistor Q5. The emitter of transistor Q5 is connected to ground. The output of timer circuit 109’s 555 timer IC is connected to the base of transistor Q5. A high signal from the 555 timer IC’s output turns the Q5 transistor on, allowing current to pass through LED2 of the test-in-progress indicator 111, lighting it up, and then pass through the Q5 transistor into ground. A low output from the 555 timer IC turns transistor Q5 off, thus turning off LED2 of test-in-progress indicator 111.

[0045] FIG. 3B depicts circuit diagrams of portions of an LTC battery health and depassivation testing apparatus (battery testing apparatus 100) according to various examples disclosed herein. The battery testing apparatus 100 includes a timed switch circuit 113 that is controlled by the output signal from the 555 timer IC of timer circuit 109. The timed switch circuit 113 may implemented with a transistor suitable for power management applications. For example, the implementation depicted in FIG. 3B uses a Fairchild(TM) FDS4465 P-channel MOSFET labeled Q9. The gate of the Q9 transistor is connected to the OUTPUT terminal of the 555 timer IC of timer circuit 109. The drain terminal of the Q9 transistor is connected to the output of voltage comparator 117. The source terminal of Q9 is connected to the flip-flop SET input which is included in the indicator drive circuitry 121.

[0046] The comparator 117 may be implemented with a comparator IC such as the Texas Instruments(TM) LM311 P. In the implementation shown in FIG. 3B the LM311 P comparator IC is connected as follows: The 5.0 volt DC voltage supply 119 is connected to pins 7 and 8. Pin 4 in connected to ground. Pin 2 receives 3.2 volts DC which is used for the nominal voltage of a LTC battery, and pin 3 receives the voltage from the battery under test from timed switch 113. The 3.2 volt DC nominal battery voltage is the result ofa resistive voltage divider formed by 5.6kohm resistor R23 and 10kohm resistor R24 placed in series between the 5.0 volt DC voltage supply 119 and ground. Pin 1 is the output (EMIT) which connects to the indicator drive circuit 121 via output switch 129.

[0047] The indicator drive circuit 121 includes a NOR based flip-flop. This flip-flop circuit functions essentially the same as an RS flip-flop (Set-Reset flip-flop). If the SET input is high and the RESET input is low, the output Q will be high. If the RESET input is high and SET is low, the output Q will be low. If both SET and RESET are low, the output retains its current state.

[0048] So long as the battery voltage remains at 3.2 volts DC or greater the comparator 117 will maintain a high signal at the SET input of indicator drive circuit 121, that is, at the SET input of the flip-flop circuit. Once the 30 second time period for the battery test ends the output of timer circuit 109 goes low, turning off the Q9 transistor of timed switch 113. The NOR based flip-flop within the indicator drive circuitry 121 will remains at its current state. If the battery 101 voltage is 3.2 volts DC or greater, the comparator 117 output will be high while the RESET input (from test initiation switch 107) is low. This causes the Q output of the flip-flop circuit In the indicator drive circuitry 121 to be high while the Q’ output is low. This turns on transistors Q7 and Q6, driving current through LED3 to light up pass indicator 1 3. If the battery 101 voltage is less than 3.2 volts DC, the comparator 117 output will be low, causing the Q’ output of the flip-flop circuit of the indicator drive circuitry 121 to be high while the Q output is low. This turns on transistors Q10 and Q8, driving current through LED4 to light up fall indicator 125.

[0049] This apparatus will simply, and automatically, depassivate the battery (if possible) and will provide visual feedback to the user if the depassivation procedure was sufficiently able to recover the current-carrying capability of the battery. The apparatus is simple and meant for a person that has little to no electrical knowledge of the functionality of the battery or the circuit that it is meant to go in. The user simply connects the battery to the apparatus, pushes a “start" button (test initiation switch 107) and then reads the appropriate visual LED indicators to determine whether the battery is “good” or “bad”.

[0050] There are 4 LED indicators and / or other types of indicators on the apparatus: 1) An indicator that will tell the user that the battery is connected backwards 2) An indicator that will tell the user that the test is in process 3) An indicator that will tell theuser that the battery is suitable for use and 4) An indicator that will tell the user that the batter is not suitable for use. Indicators #3 and #4 will not be illuminated at the same time. This apparatus can be duplicated as many times as necessary to quickly test large numbers of cells. This will provide a simple visual indicator that will help decide whether to keep (or scrap) cells that have been in storage for some time. This apparatus can also be used to maintain batteries that have been sitting in storage by removing passivation every so often, which will also reduce scrap. In the disclosure of the various examples the phrase “aligned with” is used to describe the position of an opening with respect to a component. In this context, an object inserted straight into an opening that is aligned with a component would come in contact with the component.

[0051] One of ordinary skill will appreciate that the exact dimensions and materials are not critical to the disclosure and all suitable variations should be deemed to be within the scope of the disclosure if deemed suitable for carrying out the objects of the disclosure.

[0052] One of ordinary skill in the art will also readily appreciate that it is well within the ability of the ordinarily skilled artisan to modify one or more of the constituent parts for carrying out the various examples of the disclosure. Once armed with the present specification, routine experimentation is all that is needed to determine adjustments and modifications that will carry out the present disclosure.

[0053] For the sake of brevity, the word “connected” has sometimes been used in this disclosure to mean “electrically connected”. The phrase “electrically connected” is used in the descriptions of the various examples. Two components that are “electrically connected” either have their leads fastened together (e.g., soldered together) or are connected by — or via — more conductive components. An LED connected to a 5.0 volt DC power supply via a resistor means that the resistor is in series between the LED and the 5.0 volt DC power supply so that a conductive path is established from the LED through the resistor to the 5.0 volt DC power supply. Also, two components may be connected via a third component even if the path only passes through terminal of the third component. For example, a first component (e.g., transistor drain terminal) may be electrically connected to a second component (e.g., power supply) via a third component (e.g., a capacitor) if the connectivity path passes through a terminal of the third component, the capacitor, which is tied to ground. Circuits are often configured this waywith capacitors to avoid spurious signals. The capacitor acts on the circuit even though the signal path only goes through its terminal.

[0054] The phrase “detachably connected” is used in the descriptions of the various examples. Two components are “detachably connected” if they can be separated and reattached without damaging the two components. For example, a nut screwed onto a bolt is detachably connected to the bolt. However, two pieces of metal welded together are not considered to be detachably connected to each other. Separating the two pieces of welded metal would damage the weld joint of the two pieces of metal.

[0055] The word “controllable" is used in the descriptions of the various examples to describe a manner in which a component can perform an action or get to a particular state. For example, a switch may be controllable to connect and disconnect a power supply. In this context, the word “controllable” means that the switch can be controlled to do something — e.g., connect and disconnect a power supply. The control may come from a control signal or control line — wired or wireless — from another component. The phrase “controllable electrical connection” is used in the descriptions of the various examples. A “controllable electrical connection” may be controlled — for example, by a controller, a timer, or other logic — to either provide an electrical connection or to be an open circuit.

[0056] The above examples are for illustrative purposes and are not intended to limit the scope of the disclosure or the adaptation of the features described herein. Those skilled in the art will also appreciate that various adaptations and modifications of the above-described preferred examples can be configured without departing from the scope and spirit of the disclosure. Therefore, it is to be understood that, within the scope of the appended claims, the disclosure may be practiced other than as specifically described.

Claims

CLAIMSWhat is claimed is:

1. A health and depassivation testing apparatus for a battery characterized by a battery voltage, the apparatus comprising:a pair of removable electrodes including a first removable electrode configured to detachably connect to a first battery terminal of the battery, and second removable electrode configured to detachably connect to a second battery terminal of the battery;a polarity protection circuit electrically connected to one electrode of the pair of removable electrodes;a polarity error indicator including a first lead electrically connected to the first removable electrode and a second lead electrically connected to the second removable electrode;a test initiation switch with an initiate output terminal and a reset output terminal;a timer circuit with a timer input terminal and a timer output terminal, the timer input terminal being electrically connected to the initiate output terminal of the test initiation switch;a test-in-progress indicator electrically connected to the timer output terminal of the timer circuit;a current sink circuit electrically connected to the first removable electrode; a DC power supply;a comparator circuit including a first comparator input electrically connected to the first removable electrode to provide the battery voltage to the comparator circuit, the comparator circuit including a second comparator input electrically connected to the DC power supply; andan indicator drive circuit electrically connected to the comparator circuit.

2. The apparatus of claim 1, wherein the first battery terminal is a cathode and the second battery terminal is an anode, the apparatus further comprising:a pass indicator electrically connected to the indicator drive circuit.

3. The apparatus of claim 2, wherein the polarity protection circuit is electrically connected to the cathode of the battery via the first removable electrode, the apparatus further comprising:a fail indicator electrically connected to the indicator drive circuit.

4. The apparatus of claim 2 or claim 3, wherein the current sink circuit is electrically connected by a controllable electrical connection to the cathode of the battery via the polarity protection circuit and the first removable electrode; andwherein the timer circuit maintains the controllable electrical connection between the cathode of the battery and the current sink circuit for a predefined period of time.

5. The apparatus of claim 4, wherein the timer circuit is electrically connected to the current sink circuit; andwherein the predefined period of time is 75 seconds + / - 60 seconds.

6. The apparatus of claim 5, wherein the predefined period of time is 30 + / - 10 seconds.

7. The apparatus of any one of claims 2 to 6, wherein the first comparator input of the comparator circuit is electrically connected to the cathode of the battery via the polarity protection circuit and the first removable electrode,wherein the second comparator input is electrically connected to the DC power supply via a voltage terminal of a voltage divider; andwherein the voltage terminal is maintained at a nominal test voltage for the battery.

8. The apparatus of claim 7, wherein the comparator circuit outputs a pass output if the battery voltage is equal to or greater than the nominal test voltage; andwherein the comparator circuit outputs a fail output if the battery voltage is less than the nominal test voltage.

9. The apparatus of any one of claims 2 to 8, wherein the timed switch is electrically connected to the cathode of the battery via the polarity protection circuit and the first removable electrode.

10. The apparatus of any one of claims 1 to 9, wherein the indicator drive circuit is electrically connected to the comparator circuit.

11. The apparatus of any one of claims 1 to 10, wherein the polarity error indicator includes an LED and a resistor; andwherein the DC power supply is a 5.0 volt DC power supply.

12. The apparatus of any one of claims 1 to 11, wherein the DC power supply is an AC-DC converter that is configured to plug into a wall socket.

13. A health and depassivation testing circuitry apparatus for a battery characterized by a battery voltage, the apparatus comprising:a pair of removable electrodes including a first removable electrode configured to detachably connect to a first battery terminal of the battery, and second removable electrode configured to detachably connect to a second battery terminal of the battery;a P-channel MOSFET transistor including a source terminal, a gate terminal electrically connected to the second removable electrode, and a drain terminal electrically connected to the second removable electrode;a DC power supply;a first LED including a first LED cathode terminal electrically connected to the first removable electrode and including a second LED anode terminal electrically connected to the second removable electrode via a first resistor, wherein the first LED is configured to indicate a polarity error;a test initiation switch with an initiate output terminal and a reset output terminal;a timer integrated circuit with a timer input terminal and a timer output terminal, the timer input terminal being electrically connected to the initiate output terminal of the test initiation switch;a second LED in series with a second resistor, the second LED including a second anode terminal controlled by the timer integrated circuit, and including a second cathode electrically connected to ground, wherein the second LED is configured to indicate test-in-progress;a current sink circuit including a resistor electrically connected to the source terminal of the P-channel MOSFET transistor;a comparator circuit including a comparator output terminal, a first comparator input terminal electrically connected to the first removable electrode to provide the battery voltage to the comparator circuit, and a second comparator input terminal electrically connected to the DC power supply;an indicator drive circuit including an indicator drive input electrically connected to the comparator output.

14. The apparatus of claim 13, wherein the first battery terminal is a cathode and the second battery terminal is an anode, the apparatus further comprising:a third LED electrically connected to an indicator drive output of the indicator drive circuit.

15. The apparatus of claim 14, wherein the polarity protection circuit is electrically connected to the cathode of the battery via the first removable electrode, the apparatus further comprising:a fail indicator electrically connected to the indicator drive circuit.

16. The apparatus of any one of claims 13 to 15, wherein the current sink circuit is electrically connected by a controllable electrical connection to the cathode of the battery via the polarity protection circuit and the first removable electrode; andwherein the timer circuit maintains the controllable electrical connection between the cathode of the battery and the current sink circuit for a predefined period of time.

17. The apparatus of claim 16, wherein the timer circuit is electrically connected to the current sink circuit; andwherein the predefined period of time is 75 seconds + / - 60 seconds.

18. The apparatus of claim 17, wherein the predefined period of time is 30 + / - 10 seconds.

19. The apparatus of any one of claims 14 to 18, wherein the first comparator input of the comparator circuit is electrically connected to the cathode of the battery via the polarity protection circuit and the first removable electrode,wherein the second comparator input is electrically connected to the DC power supply via a voltage terminal of a voltage divider; andwherein the voltage terminal is maintained at a nominal test voltage for the battery.

20. The apparatus of claim 19, wherein the comparator circuit outputs a pass output if the battery voltage is equal to or greater than the nominal test voltage; and wherein the comparator circuit outputs a fail output if the battery voltage is less than the nominal test voltage.

21. The apparatus of any one of claims 14 to 20, wherein the timed switch is electrically connected to the cathode of the battery via the polarity protection circuit and the first removable electrode.

22. The apparatus of any one of claims 13 to 21, wherein the indicator drive circuit is electrically connected to the comparator circuit.

23. The apparatus of any one of claims 13 to 22, wherein the polarity error indicator includes an LED and a resistor; andwherein the DC power supply is a 5.0 volt DC power supply.

24. The apparatus of any one of claims 13 to 23, wherein the DC power supply is an AC-DC converter that is configured to plug into a wall socket.

25. A health and depassivation testing apparatus for a battery characterized by a battery voltage, the apparatus comprising:a pair of electrodes including a first electrode configured to detachably connect to a cathode of the battery, and second electrode configured to detachably connect to an anode of the battery;a polarity protection circuit electrically connected to one electrode of the pair of electrodes;a polarity error indicator including a first lead electrically connected to the first electrode and a second lead electrically connected to the second electrode;a test initiation switch with an initiate output terminal and a reset output terminal;a timer circuit with a timer input terminal and a timer output terminal, the timer input terminal being electrically connected to the initiate output terminal of the test initiation switch;a test-in-progress indicator electrically connected to the timer output terminal of the timer circuit;a current sink circuit electrically connected to the first electrode;a DC power supply;a comparator circuit including a first comparator input electrically connected to the first electrode to provide the battery voltage to the comparator circuit, the comparator circuit including a second comparator input electrically connected to the DC power supply; andan indicator drive circuit electrically connected to the comparator circuit.

26. A health and depassivation testing apparatus for a battery characterized by a battery voltage, the apparatus comprising:a pair of removable electrodes including a first removable electrode configured to detachably connect to a first battery terminal of the battery, and second removable electrode configured to detachably connect to a second battery terminal of the battery;a polarity error indicator including a first lead electrically connected to the first removable electrode and a second lead electrically connected to the second removable electrode;a test initiation switch with an initiate output terminal and a reset output terminal;a timer circuit with a timer input terminal and a timer output terminal, the timer input terminal being electrically connected to the initiate output terminal of the test initiation switch;a test-in-progress indicator electrically connected to the timer output terminal of the timer circuit;a DC power supply;a comparator circuit including a first comparator input electrically connected to the first removable electrode to provide the battery voltage to the comparator circuit, the comparator circuit including a second comparator input electrically connected to the DC power supply; andan indicator drive circuit electrically connected to the comparator circuit.

27. The apparatus of claim 26, wherein the first battery terminal is a cathode and the second battery terminal is an anode, the apparatus further comprising:a pass indicator electrically connected to the indicator drive circuit; and a fail indicator electrically connected to the indicator drive circuit.

28. The apparatus of claim 27, further comprising a current sink circuit is electrically connected by a controllable electrical connection to the cathode of the battery via a polarity protection circuit and the first removable electrode; andwherein the timer circuit maintains the controllable electrical connection between the cathode of the battery and the current sink circuit for a predefined period of time.

29. The apparatus of claim 28, wherein the timer circuit is electrically connected to the current sink circuit; andwherein the predefined period of time is 75 seconds + / - 60 seconds.

30. The apparatus of claim 29, wherein the predefined period of time is 30 + / - 10 seconds.

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