Series Lead-Acid Charging with HF Conditioning Against Sulfation
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Solution Overview
Problem
Lead-acid batteries face issues such as sludge formation, grid corrosion, and crystalline lead sulfate formation, which reduce their capacity and reliability, and existing charging methods do not adequately address these problems.
Innovation Solution
A multi-channel charging device is used to charge and condition lead-acid batteries individually with high-frequency periodic signals between 3 MHz and 10 MHz, incorporating galvanic isolation, DC/DC converters, and RF circuits to prevent crystalline lead sulfate formation and enhance battery reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional charging methods are used for lead-acid batteries in series connection, then charging simplicity is maintained, but crystalline lead sulfate formation occurs reducing battery capacity and reliability
Solution Approach 1:
The patent applies periodic high-frequency charging pulses (3-10 MHz) superimposed on the conventional charging current. These periodic high-frequency components prevent crystalline lead sulfate formation by continuously disrupting crystal growth patterns, thereby maintaining battery reliability without complicating the charging process
Solution Approach 2:
The patent changes the frequency parameter of the charging current by superimposing high-frequency components (3-10 MHz) on top of the conventional charging current. This parameter change transforms the charging process from a simple DC current to a composite current with beneficial high-frequency characteristics that prevent harmful crystal formation
2Reliability
If individual channel charging devices are used for each battery, then each battery can be charged individually improving reliability, but device complexity increases
Solution Approach 1:
The patent combines multiple charging channels into a single integrated device that can charge multiple batteries in series connection simultaneously. Each channel includes galvanic isolation and high-frequency signal generation, but they are controlled through a unified system that reduces overall device complexity compared to using separate charging devices for each battery
Solution Approach 2:
The charging device is designed with multi-functionality to handle series connections of multiple lead-acid batteries simultaneously. Each channel can independently provide galvanic isolation and high-frequency charging pulses, making the device universally applicable to various battery configurations while maintaining a unified control structure
3Duration of action of stationary object
If high-frequency periodic signals are applied to prevent crystalline lead sulfate formation, then battery lifespan is extended, but energy consumption increases
Solution Approach 1:
The patent applies high-frequency signals at specific frequency ranges (3-10 MHz) and duty cycles that are sufficient to prevent crystalline lead sulfate formation without excessive energy input. The high-frequency component is superimposed only during charging phases, not continuously, thereby extending battery lifespan while controlling energy consumption
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 prevents the formation of disruptive crystals, extends the lifespan of lead-acid batteries, and ensures safe and reliable charging, particularly effective for open and sealed lead-acid batteries.
Implementation Method 1
it has surprisingly been found that lead sulfate crystals can be destroyed by means of high-frequency (HF) components
Implementation Method 2
Lead sulfate (PbSO4) and water are electrochemically reacted to form lead (Pb), lead dioxide (PbO2), and sulfuric acid (H2SO4) using the external voltage source SQ
Implementation Method 3
gas formation results from the electrolytic decomposition of the water contained in the dilute sulfuric acid (i.e., in the electrolyte). This process produces oxygen and hydrogen
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
Device (100) for charging rechargeable lead-acid batteries (10; 10.1, 10.2 ... 10.n), wherein the lead-acid batteries (10) are connected in series, and wherein the device (100) comprises: • a device (21) with load matching circuits, wherein the load matching circuits provide separate charging currents (IL; IL1, IL2 ... Iln), each of the load matching circuits being connected via an electrically conductive connection to the positive terminal (1) and via an electrically conductive connection to the negative terminal (2) of one of the lead-acid batteries (10; 10.1, 10.2 ... 10.n) such that each of the lead-acid batteries (10; 10.1, 10.2 ... 10.n) can be charged individually with one of the charging currents (IL; IL1, IL2 ... Iln), • an RF circuit or RF feed, which provides a provides a high-frequency, periodic signal that is applied to each of the charging currents (IL; IL1, IL2 ... Iln) to condition each of the lead-acid batteries (10; 10.1, 10.2 ... 10.n) separately in the high-frequency range.