Internal Charger System for High Voltage Battery Charging
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Solution Overview
Problem
Portable electronic devices with rechargeable batteries face challenges in charging when the battery voltage exceeds the voltage provided by standard external power sources, such as USB connections, which are typically limited to five volts.
Innovation Solution
An internal charger system with a charge controller and a single-stage DC to DC regulator that determines the maximum current output of an external power source and adjusts the charging voltage and current to suit the battery's voltage, allowing for charging even when the battery voltage is higher than the external power source, using a standardized data connector like USB.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a standardized USB connector is used for charging, then ease of operation and compatibility are improved, but the charging capability is limited to five volts which cannot charge batteries with higher operating voltages
Solution Approach 1:
A DC-to-DC regulator is introduced as an intermediary component between the USB connector and the battery. This regulator converts the 5V USB output voltage to the higher voltage required by the battery, enabling compatibility between the standardized low-voltage USB interface and high-voltage batteries while maintaining ease of operation.
Solution Approach 2:
The system dynamically changes the voltage parameter through the DC-to-DC regulator, which adjusts the output voltage from the fixed 5V USB supply to match the variable voltage requirements of the battery during charging. This allows the system to overcome the voltage limitation of the USB standard while maintaining adaptability.
2Ease of operation
If the device includes charging circuitry to charge the battery while connected to the device, then the charging function is integrated and ease of operation is improved, but the system cannot charge batteries with voltage higher than the external power source
Solution Approach 1:
The DC-to-DC regulator serves as a mediator that enables the integrated charging circuitry to overcome the voltage limitation. It receives 5V from the USB connector and transforms it to the higher voltage needed by the battery, thus maintaining both integrated charging convenience and reliable charging capability for high-voltage batteries.
3Adaptability or versatility
If external charger contacts are added to the battery pack, then the battery can be charged externally, but the device complexity and manufacturing cost increase
Solution Approach 1:
The charging function is extracted from the battery pack itself and relocated to the device's internal charging circuitry. The device includes a USB connector and DC-to-DC regulator that can charge the battery while connected, eliminating the need for additional external charger contacts on the battery pack while maintaining external charging capability.
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
Enables charging of batteries with higher operating voltages than the standard USB voltage, providing a visual indication of charging status even when the device cannot be turned on, and efficiently manages charging to prevent battery damage.
Implementation Method 1
a single-stage DC to DC regulator that transforms a voltage output from the external power source to charge the battery
Data Source
AI summary
An internal charging system controls charging of a battery used to power an electronic device when an external power source is connected to the device. The internal charging system can charge a battery that has a higher operating voltage than the voltage provided by the external power source. While charging the battery from the external power source, an internal charge controller can operate and inhibit functions of the device to indicate to user that a charging operation is commencing, and to prevent operation of the device when the battery voltage is too low to support such operation.