Battery Charge System Transition Control for Isolation Device Protection

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Solution Overview

Problem

In battery charge systems, high system loads and low battery voltages during transitions to higher voltage outputs from AC/DC adapters can cause significant power surges that exceed the rating of isolation devices, potentially damaging them or causing system failure, and existing solutions either fail to address all scenarios or increase costs by upgrading device ratings.

Innovation Solution

A battery charge system with a controller that manages power transitions by using MOSFETs and a switching converter to regulate voltage and current, allowing safe switching between battery and AC/DC adapter power sources, including a buck/boost mode to handle varying loads and voltages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If isolation devices are upgraded to handle higher power ratings, then system reliability is improved, but device cost and complexity increase

Engineering Contradiction:
Improvesystem reliabilityVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The controller performs preliminary actions by detecting adapter connection status and battery voltage levels before power transition occurs. It proactively adjusts isolation device gate signals to ensure safe transition conditions are met, preventing power surges before they can damage the isolation devices.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the operating parameters of isolation devices based on real-time conditions. The controller modulates the gate signals to MOSFETs, varying their conduction states during transition to limit power surge exposure, rather than using fixed high-power-rated devices.

Inventive Principle:
Principle #15Dynamics

2Reliability

If transition control is implemented to protect isolation devices, then device reliability is improved, but system complexity increases

Engineering Contradiction:
Improveisolation device reliabilityVSAvoidsystem complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The controller performs multiple functions: it manages normal power switching, detects adapter connection status, monitors battery voltage, and protects isolation devices during transitions. By consolidating these functions in a single controller, the system avoids adding separate protection circuits that would increase complexity.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The controller uses feedback from voltage detection circuits and connection status sensors to adjust isolation device operation. It continuously monitors system state and modifies gate signals accordingly, creating a closed-loop protection mechanism that responds to actual conditions rather than requiring over-engineered passive protection.

Inventive Principle:
Principle #23Feedback

3Duration of action of stationary object

If power surge protection is added during transitions, then isolation device durability is improved, but manufacturing cost increases

Engineering Contradiction:
Improveisolation device durabilityVSAvoidmanufacturing cost
Core Design Contradiction:
Duration of action of stationary objectVSEase of manufacture

Solution Approach 1:

The system uses its existing controller and detection circuits to provide self-protection during transitions. The controller leverages already-present voltage sensing capabilities and connection detection to automatically protect isolation devices, eliminating the need for separate protection components or expensive surge suppression hardware.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The controller changes operational parameters (gate signal timing, conduction states) of existing isolation devices to protect them during transitions. By modifying how the devices operate rather than replacing them with more robust but expensive components, the system achieves protection without increasing manufacturing cost.

Inventive Principle:
Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution effectively mitigates power surges by controlling voltage and current transitions, ensuring safe operation across different conditions without the need for costly upgrades, thereby protecting isolation devices and maintaining system integrity.

Implementation Method 1

A battery charge system with a controller that manages power transitions by using MOSFETs and a switching converter to regulate voltage and current

Methodology Applied
Scientific EffectField effect transistor operation: Conduction (electrical)

Implementation Method 2

A battery charge system with a controller that manages power transitions by using MOSFETs and a switching converter to regulate voltage and current

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10797490B2Battery charge system with transition control that protects adapter components when transitioning from battery mode to adapter mode
Publication Date: 2020.10.06 INTERSIL AMERICAS INC
  • US10797490B2 patent drawing
  • US10797490B2 patent drawing
  • US10797490B2 patent drawing

AI summary

A battery charge system including an adapter node, a system node, a battery, a first isolation switch coupled between the adapter and system nodes, a second isolation switch coupled between the battery and system nodes, a boost converter, and a controller. The controller turns off the first isolation switch and turns on the second isolation switch during a battery mode, activates the boost converter when an adapter voltage is detected, turns off the second isolation switch when the system voltage rises above the battery voltage, and turns on the first isolation switch when the system voltage rises to an operating voltage level. The boost converter may then be turned off once in the adapter mode. The second isolation switch may initially be turned on partially at a low current level when the adapter is detected, and then turned fully on when the system voltage is at the operating voltage level.