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Stephen D Rose

Jeffrey A Rose

Joseph A Cates

Eldon R Conley

James R Barker

Raymond D Cooper

A method and apparatus is provided to charge a battery including a DC charge current supply having a variable output. The charging current is varied in accordance with several sensed parameters in the circuit so that battery voltage is accurately controlled. Initially, constant charging current is applied, and upon detecting that battery voltage increases to the gassing voltage, an incremental step reduction in charging current is triggered. The step reduction causes a decrease in battery voltage, dropping it below the gassing voltage. The step reduced charging current is then applied to increase battery voltage back up to the gassing voltage, thereby triggering another step reduction in charging current. This process is repeated multiple times providing a stepped current profile, i.e., each battery voltage increase to the gassing voltage triggering a step reduction in charging current, and in turn a corresponding voltage reduction. The battery voltage, with the alternating increases and decreases, is thus defined by a saw-tooth profile with peaks at the gassing voltage. When the charging current is finally reduced to a minimum level, the sensed battery voltage triggers a termination of the stepped current reduction. Upon the battery reaching full charge, the application of charging current is terminated. In the alternative embodiment, the slope of the voltage curve is detected and analyzed to control a step up profile of the current during the initial phase of charging. The rising temperature of the battery controls a decrease in the gassing or target voltage.

Battery charging method with stepped current profile with operating

A method and apparatus is provided to charge a battery including a DC charge current supply having a variable output. The charging current is varied in accordance with several sensed parameters in the circuit so that battery voltage is accurately controlled. Initially, constant charging current is applied, and upon detecting that battery voltage increases to the gassing voltage, an incremental step reduction in charging current is triggered. The step reduction causes a decrease in battery voltage, dropping it below the gassing voltage. The step reduced charging current is then applied to increase battery voltage back up to the gassing voltage, thereby triggering another step reduction in charging current. This process is repeated multiple times providing a stepped current profile, i.e., each battery voltage increase to the gassing voltage triggering a step reduction in charging current, and in turn a corresponding voltage reduction. The battery voltage, with the alternating increases and decreases, is thus defined by a saw-tooth profile with peaks at the gassing voltage. When the charging current is finally reduced to a minimum level, the sensed battery voltage triggers a termination of the stepped current reduction. Upon the battery reaching full charge, the application of charging current is terminated.

Battery charging method with stepped current profile and associated

An apparatus for connecting a battery charger to an electric vehicle including a battery and a drive motor in an electrical circuit includes first and second cooperating connectors. The connectors are adapted for mating in electrical contact. A bracket is provided for mounting the first connector to the vehicle. The second connector is mounted on the distal end of cables leading from the battery charger. The apparatus also includes a switch for interrupting the electrical circuit between the battery and the drive motor prior to mating of the first and second connectors. The invention also relates to a battery charging system incorporating a battery charger, a charger receptacle mounted on the vehicle and a plug for operatively connecting the battery charger to the charger receptacle. Both the charger receptacle and the plug include cooperating electrical contacts. A door is pivotally mounted over the charger receptacle for covering the electrical contacts of the receptacle when not in mating electrical contact with the electrical contacts of the plug. The battery charging system also includes a switch for interrupting the electrical circuit between the battery and the drive motor of the vehicle prior to mating of the plug and receptacle.

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Irvine, KY, United States of America

Stephen D Rose