Battery Charging Circuit With Power Factor Correction and Waveform Shaping
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Solution Overview
Problem
Conventional battery charging systems are inefficient and costly, requiring high-power electronics for rapid recharging, which can damage batteries and prolong charging time, while slower systems fail to provide quick service due to excessive component complexity and energy loss.
Innovation Solution
A power supply circuit with a converter and voltage booster, combined with a DC/DC converter and charge waveform shaping circuit, corrects power factor loss and generates a shaped charge waveform to efficiently charge batteries with reduced component count, optimizing energy transfer and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-power electronics are used for rapid recharging, then charging speed is improved, but battery degradation increases and cost increases
Solution Approach 1:
The patent applies periodic action by using pulsed charging current instead of continuous high current. The controller switches the charging current on and off in controlled pulses, allowing the battery to charge rapidly during active pulses while resting during off periods. This periodic approach enables faster overall charging while reducing thermal stress and chemical degradation compared to sustained high-current charging.
2Productivity
If high-power electronics are used for rapid recharging, then charging speed is improved, but cost increases
Solution Approach 1:
The patent merges the charging circuit control functions into a microcontroller unit that integrates multiple control tasks. The microcontroller manages current regulation, pulse timing, voltage monitoring, and safety features in a single integrated component, replacing what would traditionally require multiple separate high-power electronic components. This consolidation reduces system cost while maintaining rapid charging capability.
3Device complexity
If conventional charging circuits are used, then component count is reduced, but energy loss increases
Solution Approach 1:
The patent implements feedback control where the microcontroller continuously monitors charging voltage and current, comparing actual values against target profiles. Based on this feedback, the controller dynamically adjusts the charging parameters in real-time to optimize energy transfer efficiency. This closed-loop control minimizes energy losses from excessive voltage or current without requiring additional passive energy recovery components.
4Device complexity
If conventional charging circuits are used, then component count is reduced, but charging efficiency decreases
Solution Approach 1:
The patent applies dynamics by implementing adaptive charging control where the microcontroller continuously adjusts charging parameters based on real-time battery conditions. The system dynamically modifies current magnitude, pulse duration, and rest periods according to battery state of charge, temperature, and impedance changes. This dynamic adaptation maximizes charging efficiency at each stage without requiring complex hardware switching networks.
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 reduces the number of components in the charging circuit, conserves energy, and enhances charging efficiency, providing faster charging with reduced battery degradation and lower operational costs.
Implementation Method 1
a power supply circuit with a converter portion receiving a power signal and a voltage booster portion
Implementation Method 2
converting, at the power supply circuit, the AC component of the input power signal into a direct current (DC) power signal
Implementation Method 3
voltage booster portion... converting, at the power supply circuit, the AC component of the input power signal into a direct current (DC) power signal
Implementation Method 4
a switch in communication with a processor executing instructions to generate a control signal, the switch operable connected to a transformer to receive and alter the DC power signal to produce a shaped charge waveform
Data Source
AI summary
An optimized charge signal shaping circuit is presented such that components of the charge signal circuit arrangement may be operable with fewer components and/or processing overhead than other approaches, thereby reducing costs, using less printed circuit board (PCB) real estate, and being computationally less complicated, among other advantages. In one particular implementation, portions of a power supply circuit may be combined with portions of a charge signal shaping circuit to leverage common functions and component characteristics of the portions, including a direct current/direct current (DC/DC) converter circuit. A reduced charge circuit may take advantage of each component including similar functions and/or circuit devices to reduce the overall number of components used in the charge circuit to reduce the overall footprint, conserve charging energy lost to the redundant components, and reduce the overall cost.