Patent Document

FIELD OF THE DISCLOSURE 
       [0001]    The present disclosure relates to the field of rechargeable batteries and energy cells for rechargeable batteries. More specifically, the present disclosure relates to circuitry and a method for balancing the discharge of battery cells. 
       BACKGROUND OF THE DISCLOSURE 
       [0002]    Batteries are a convenient source of electrical energy for many types of portable and/or mobile electronics. A typical battery is formed by the connection of a number of electrical cells connected in a series configuration. Many types of batteries include rechargeable cells, such that when an outside energy source is applied to the battery cells energy is stored within the cells. While many chemical combinations for the cathode and the anode of the battery cells exist, some commonly used combinations include nickel cadmium (NiCd), nickel metal hydride (NiMH), and lithium ion (Li-Ion) compositions. 
         [0003]    While the rechargeable battery cells provide a convenient source of power, the rechargeable battery cells do not have an infinite life span and the ability of the cells to hold a charge degrades over the lifetime of the cell. Furthermore, battery cells leak energy and lose charge during periods of non-use or storage. These periods of non-use may occur while the cells are being held by a manufacturer before the cells are assembled into a battery, or while the cells are assembled into the battery, but the battery has not yet been sold, or during long periods of non-use of the battery by the consumer. The cell leakage is exacerbated by the presence of heat, which may affect batteries that are not stored in a temperature controlled environment. Alternatively, the cell leakage due to heat may affect a battery, such as a back up battery, that is held in close proximity to other normally operating electrical circuits that give off heat. Furthermore, due to the internal resistance of the battery, battery cells may not discharge evenly within the battery. All of these factors cause each battery cell to hold a different level of charge in comparison to the other cells in the battery. These different levels of charge can result in unpredictable indications of low battery and possible inadvertent power shut downs. 
         [0004]    Battery monitors are used to monitor the remaining battery discharge time by monitoring both the total charge of all the battery cells and the charge on each individual cell. Typically, a predetermined minimum charge threshold is established for both the total battery charge and for the individual cell charge. If either measure falls below the respective predetermined minimum threshold, the battery terminates discharge, cutting the power to the electronic device. Typically, the individual cell predetermined threshold accounts for possible cell imbalance by allowing an individual cell to operate at a charge level lower than that cell&#39;s fractional share of the total battery charge predetermined threshold. For example, if a battery has three cells and the battery cell predetermined minimum charge is 9 volts, the individual cell predetermined minimum charge may be 2.4 volts instead of the 3 volts that would be one third of the 9 volt total. The battery may also produce an indication of the remaining battery charge and this indication is determined by using the total cell charge of all the battery cells. Therefore, if the cells are unbalanced, one cell may fall below the individual cell charge threshold before the total battery charge reaches the total battery charge minimum threshold. This results in the battery terminating the supply of a charge before the total battery charge has reached the minimum threshold value. This reduces the operable battery time between charges and produces an unpredictable termination of the battery discharge. 
         [0005]    Similarly when the battery is charging, the cells are charged until the total charge on the cells reaches a threshold value. Additionally, charging is also terminated when the charge on any one individual cell reaches predetermined maximum charge threshold. Therefore, if the cells are unbalanced, one cell may reach the individual cell maximum charge threshold, while the total charge of the battery has not yet achieved full battery charge. This results in the battery not being charged to its full charge potential, which reduces the operable battery time between charges. 
         [0006]    Methods and systems have been developed to attempt to remedy the problem of cell unbalance. The manual process of measuring the state of charge of each cell and matching the cells with similar charges when they are assembled into a battery is inaccurate and very time consuming. Furthermore, this manual process does not address any cell leakage that may occur after battery assembly. Alternatively, active cell balancing may be implemented using a series combination of a load resistor and a transistor placed in parallel with each individual cell, where the resistor and transistor shunt current during charge of the battery cells. This type of cell balancing is achieved by software using a complex control algorithm and merely emulates the cell charge balance rather than forcing an inherent cell charge balance and therefore is sensitive to many sources of error, such as initial cell charge and the cell open circuit voltage. 
         [0007]    Therefore, it is desirable in the field of rechargeable batteries to provide a battery that is capable of balancing the charge of each of the cells to maximize the operable battery discharge time. It is also desirable for a battery that achieves cell charge balancing that is not as dependant on complex software algorithms to emulate the forcing of inherent cell balance. It is desirable for a battery that achieves cell balancing and uses measured values of cell characteristics in controlling the cell balancing. Furthermore, a method for balancing the charge on the cells of a battery is desirable. It is desirable for the method to be operable prior to assembly of the cells into a battery, or for the method to be operable after the battery has been constructed. 
       SUMMARY OF THE INVENTION 
       [0008]    An embodiment of the battery in the present disclosure comprises a plurality of cells that produce a battery charge and the battery comprises a plurality of switches connected between the battery cells and a load, the switches being configurable such that the battery cells are connected in a normal configuration or alternatively in a balance configuration. 
         [0009]    In a further embodiment, when the cells are configured in a balance configuration, the cells are connected to a discharge load, wherein in an embodiment, the discharge load comprises a constant-current, constant-voltage discharge load. 
         [0010]    In another embodiment, the discharge load is connected to control circuitry, such that the electrical properties of the discharge load may be modified during the discharge of the battery cells. 
         [0011]    In an embodiment of the method in the present disclosure, a balancing circuitry is attached to at least one electrical cell, wherein the balancing circuitry comprises a programmable load and a voltage monitor. 
         [0012]    In a further embodiment, the programmable load is operated to draw a current based on the maximum recommended discharge current for at least one cell until the voltage of at least one cell reaches the minimum recommended discharge voltage. 
         [0013]    In another embodiment of the method, the method is performed before the cells are assembled into a battery. 
         [0014]    In a still further embodiment, the method is performed before the battery is recharged. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIGS. 1   a - c  depict schematic diagrams of the cells of a battery at various states of charge balance and imbalance; 
           [0016]      FIG. 2  depicts a schematic diagram of an embodiment of the cell balancing circuitry; 
           [0017]      FIG. 3  depicts an embodiment of the cell balancing battery; 
           [0018]      FIG. 4  depicts a schematic diagram of an embodiment of the cell balancing battery in a normal configuration; and 
           [0019]      FIG. 5  depicts a schematic diagram of an embodiment of the cell balancing battery in a balancing configuration. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]      FIGS. 1   a - c  depict a series of schematic diagrams of a battery  10  comprising electrical cells C 1 , C 2 , and C 3  connected in series. The battery  10  comprises a positive terminal  12  and a negative terminal  14 . The total charge of the battery  10  is the voltage between the positive terminal  12  and the negative terminal  14 . An electronic device  16  or other type of electrical load is connected to the battery  10  at the positive terminal  12  and the negative terminal  14  by a load switch  18 . The load switch  18  may alternatively be another form of suitable electrical connection between the electronic device  16  and the terminals  12  and  14 , respectively, that is not necessarily a switch. When the battery  10  is connected to the electronic device  16 , the battery  10  provides the electronic device  16  with a supply of electrical charge. The electronic device  16  uses this charge to operate. 
         [0021]    Cells C 1 , C 2 , and C 3  are connected in series; therefore the individual voltage of each of the cells is summed to determine the total voltage of the battery  10 . The charge or voltage of the battery  10  is typically monitored by a fuel gauge (not depicted) consisting of a coulomb counter and a voltage monitor to determine when the battery  10  has become discharged. This determination is made when the voltage of the battery  10  drops below a predetermined battery minimum voltage threshold. Upon the detection of a battery voltage below the minimum voltage threshold, one of the switches  18  is opened such that the battery  10  terminates discharge and no power is supplied to the electronic device  16 . Alternatively, the battery  10  may terminate battery discharge upon the detection of any one of the cells C 1 , C 2 , or C 3  having a charge that is below a predetermined cell voltage threshold. During recharge, the battery  10  is determined to be charged when the total battery voltage between positive terminal  12  and negative terminal  14  reaches a predetermined maximum voltage threshold. Upon reaching this maximum voltage threshold, the battery does not accept additional charge. Similarly, the charging of the battery  10  will be terminated upon the voltage of any single cell C 1 , C 2 , or C 3  reaching a predetermined cell maximum voltage threshold. 
         [0022]    As an exemplary description, hypothetical voltages have been added to each of the cells C 1 , C 2 , and C 3  in  FIG. 1   a.  In this example, the battery discharge minimum voltage threshold is 9.0 volts and the cell discharge minimum voltage is  2 . 4  volts. As depicted in  FIG. 1   a,  the voltages of the cells C 1 , C 2 , and C 3  are relatively balanced and the total battery voltage equals 8.9 volts. Since 8.9 volts is below the battery discharge threshold voltage of 9.0 volts, the battery is determined to be discharged and the battery discharge is terminated and no power is supplied to the electronic device  16 . The battery  10  depicted in  FIG. 1   a  has used all or substantially all of the potential charge in each of the cells during the operation of the battery  10 . Therefore, the lifespan of the charge on the battery  10  is maximized and the prediction of the operating time remaining for the battery should be relatively accurate due to the even discharge of each of the cells. 
         [0023]      FIG. 1   b  depicts a battery  10  in which the cells C 1 , C 2 , and C 3  are unbalanced as C 1  has 2.3 volts, C 2  has 3.5 volts, and C 3  has 3.4 volts. In the example of  FIG. 1   b,  the total battery voltage is 9.2 volts, which is above the battery discharge minimum threshold of 9.0 volts; however, the charge of C 1  is 2.3 volts which is below the cell discharge minimum voltage threshold of 2.4 volts. Therefore, the battery  10  terminates the supply of the charge to the electronic device  16 . This is an inefficient operation as a substantial amount of charge remains in cells C 2  and C 3  that has not been utilized by the battery  10 . Therefore, the life of the battery charge is shorter than it necessarily needs to be and the battery  10  must be recharged more often. Furthermore, the total battery voltage of the battery  10  in  FIG. 1   b  is 9.2 volts which is still above the battery discharge voltage threshold. This can lead to an improper prediction of remaining operating time as the battery voltage is still above the battery discharge voltage threshold, yet the battery has terminated discharge. This inaccurate prediction of the remaining operating time can produce undesired, or potentially dangerous results if the electronic device being powered by the battery  10  cuts off the supply of power prior to the predicted operating time. 
         [0024]    Unbalanced cell charge also adversely effects the recharging of a battery  10  as depicted in  FIG. 1   c.  In the example depicted in  FIG. 1   c  the battery charge maximum voltage threshold is 12.3 volts while the cell charge maximum voltage is 4.35 volts. As depicted in  FIG. 1   c,  the battery voltage equals only 12 volts, which is below the battery charge maximum voltage threshold of 12.3 volts. However, because cell C 1  has been charged to a level of 4.4 volts, the battery  10  has completed the battery&#39;s charge cycle. Therefore the battery  10  has completed charging, yet it as not been completely charged. Therefore, the unbalance of the voltage in C 1  as compared to the voltage of cells C 2  and C 3  limits the recharging of the battery  10  to a charge level that is lower than a full recharge. 
         [0025]    This limiting of the battery recharge further reduces the operating time between charge and discharge states of the battery  10 , resulting in reduced operational life of the battery  10 . It is desirable that the charge in each of the cells is balanced such that no prematurely discharged cell prematurely initiates the termination of the charge supplied by the battery  10 , nor that additional remaining charge on any individual cell reduces the total amount of charge added to the battery  10  during recharge. 
         [0026]      FIG. 2  is a schematic diagram of the battery  10  comprising cells C 1 , C 2 , and C 3  connected to balancing circuitry  20  by the load switch  18  connected to terminals  12  and  14 . The balancing circuitry  20  may comprise a constant-current, constant-voltage (CCCV) load that connects to the cells C 1 , C 2 , and C 3  in parallel, such that the same voltage from the CCCV load is applied to each of the cells, C 1 , C 2 , and C 3 . The CCCV load may be a programmable load  22 . The programmable load  22  may comprise a current sync or a variable resistor; however, it is understood that many other suitable electrical components may be used. The balancing circuitry  20  may further comprise a voltage monitor  24  to monitor the voltage across the programmable load  22 . The parallel connection of the cells C 1 , C 2 , and C 3  to the balancing circuitry  20  forces the balance of cells C 1 , C 2  and C 3  in several cell characteristics. These characteristics include the cell voltage, state of charge, and the remaining cell capacity. When the cells C 1 , C 2 , and C 3  are connected to the balancing circuitry  20 , all of the cells are chemically discharged using the programmable load  22  and monitored by the voltage monitor  24  that make up the balancing circuitry  20 . 
         [0027]    The programmable load  22  may be adjusted or programmed to control the discharge current drawn through the load  22 . The current drawn by the programmable load  22  may be based on the cell manufacturer&#39;s maximum discharge current for each of the cells in the battery  10 . The discharge current is drawn until the cell voltage reaches the cell manufacturer&#39;s minimum discharge voltage. The discharge current is then decreased to maintain a constant voltage equal to the cell manufacturer&#39;s minimum discharge voltage until the discharge current tapers to a predefined current level. This process provides an inherent balance of the voltage, state of charge, and remaining capacity at the chemical discharge voltage threshold with minimal effects due to internal cell impedance. This process and circuitry also achieves the balance in the shortest amount of time without violating the cell manufacturer&#39;s maximum discharge current or minimum discharge voltage recommendations. Once the cells have been balanced during manufacture, the cells can be reconfigured in a series of connections to define the battery. 
         [0028]      FIG. 3  depicts a battery  26  with a battery balancing assembly  27 . The battery balancing assembly comprises a plurality of switches, S 1 , S 2 , and S 3  that are connected to each of the cells C 1 , C 2 , and C 3 . In an embodiment of the battery balancing assembly  27 , the switches may comprise MOSFETs; however, many other suitable circuitry components and configurations for the switches may be used. The switches are controlled by a controller  28  to open or close the switches such that the battery balancing assembly  27  is in a desired configuration which may be a normal configuration or a balance configuration. In the normal configuration, the cells C 1 , C 2 , and C 3  are connected in series between the positive terminal  12  and the negative terminal  14  and the load switches  18  connect the battery to the electronic device  16 . In the balance configuration, the cells C 1 , C 2 , and C 3  are connected in parallel between the positive terminal  12  and the negative terminal  14  and the load switches  18  connect the battery to the balancing circuitry  20 . 
         [0029]    The positive terminal  12  and the negative terminal  14  are connected to a load switch  18  such that the load switch  18  is able to toggle between a load terminal  30  and a balance terminal  32 . The load terminal  30  is connected to an electronic device  16  or other type of load that is to be powered by the battery  26 . The balance terminal  32  is connected to the balancing circuitry  20  which comprises the programmable load  22  and the voltage monitor  24 . A controller  28  may be connected to the switches, S 1 , S 2 , and S 3 , the load switches  18 , the programmable load  22 , and the voltage monitor  24 . The controller  28  may control these various components by sending a control signal to each of these components via the proper lead  34  that connects the controller  28  to the component. In the embodiment of  FIG. 3 , the controller  28  comprises a push button (not depicted) that may be manually activated to switch the battery  26  between the operating configuration and the discharge configuration. Alternatively, in a contemplated embodiment of the battery  26 , the controller  28  comprises software that controls the switching between the operating configuration and the discharge configuration. This software may use sensed values of the battery voltage obtained by voltage sensors (not depicted) or individual voltages across one or more of the cells in determining the proper configuration for the battery  26 . 
         [0030]      FIG. 4  depicts the battery  26  after the controller  28  has sent control signals to operate the battery  26  in the normal configuration. The controller  28  has provided a control signal to switches S 1  and S 2  such that the switches are in an open state such that no current flows through the switches S 1  and S 2 . Switches S 1  and S 2  are depicted in  FIG. 4  in dashed lines to denote a deactivated state. The controller  28  has sent a control signal to switch S 3  such that switch S 3  is in a closed state, thereby allowing current to flow through the switch S 3 . The open state of switches S 1  and S 2  combined with the closed state of switch S 3  connects the cells C 1 , C 2 , and C 3  in series with positive terminal  12  and negative terminal  14 . 
         [0031]    The controller  28  controls the load switches  18  to connect the positive terminal  12  and the negative terminal  14  to the load terminals  30 . The combined charge from cells C 1 , C 2 , C 3  is provided in series to the electronic device  16 . This operating configuration supplies charge from the battery  26  to the electronic device  16  and may operate as such until a detection circuitry (not depicted) which may comprise voltage sensors as is commonly known in the field of the invention, determines that either the total charge on the battery has fallen below the minimum battery threshold voltage or the voltage of the cells C 1 , C 2 , or C 3  has fallen below the minimum cell threshold voltage. Upon the crossing of either minimum threshold, the battery will terminate the supply of charge to the electronic device  16 . In the embodiment shown, the controller  28  controls the load switch  18  to disengage the load terminals  30 . 
         [0032]    Once the battery  26  has ceased in providing charge to the electronic device  16 , but prior to the recharging of the cells C 1 , C 2 , and C 3  of the battery  26 , the controller  28  changes the configuration of the switches, S 1 , S 2 , and S 3 , as well as the load switches  18 , to a balance configuration as depicted in  FIG. 5 .  FIG. 5  depicts a schematic diagram of the battery  26  after the controller  28  has sent control signals along leads  34  to switches S 1 , S 2 , and S 3  such that S 1  and S 2  are placed in a closed state and switch S 3  is changed to an open state. This configuration of switch states places the cells, C 1 , C 2  and C 3  of the battery  26  in a balance configuration such that the cells, C 1 , C 2  and C 3  are connected in parallel with the positive terminal  12  and the negative terminal  14 . The controller  28  further controls the load switches  18  to connect the positive terminal  12  and the negative terminal  14  respectively to the balance terminals  32 . The balance terminals  32  are connected to the balancing circuitry  20  which comprises the programmable load  22  and the voltage monitor  24 . Therefore, the cells C 1 , C 2 , and C 3  are connected in parallel to the programmable load  22  and the voltage monitor  24 . 
         [0033]    Once the cells C 1 , C 2 , and C 3  are connected in the parallel balance configuration, the programmable load  22  may be operated such as to balance the charge in the cells C 1 , C 2  and C 3  to evenly discharge the cells to a complete chemical discharge before these cells are recharged. The programmable load  22  may receive control signals from the controller  28  via lead  34  connected to the programmable load  22 . The voltage monitor  24  may send signals indicative of the voltage across the programmable load  22  to the controller  28  vial lead  36 . The controller  28  may send control signals to the programmable load  22  based upon the monitored voltage to control the resistance value of the programmable load  22  and the resulting current drawn by the programmable load  22 . 
         [0034]    The controller  28  may send a control signal to the programmable load  22  such that the resistance of the programmable load  22  changes to draw a constant current out of the battery  26  based on the maximum recommended discharge current for each of the cells C 1 , C 2 , and C 3 . The discharge current may be determined by the controller  28  as being the maximum recommended discharge current for an individual cell multiplied by the total number of cells that are connected in parallel to the balancing circuitry  20 . Alternatively, the discharge current drawn by the adjustable load  22  may be the summation of the maximum recommended discharge currents for each of the cells utilized in the battery  26 . The discharge current may be drawn until the voltage of at least one of the parallel cells C 1 , C 2 , or C 3  reaches the minimum recommended discharge voltage for the cell. After this has been detected, the controller  28  may send a control signal to the adjustable load  22  such that the resistance of the adjustable load  22  is gradually increased so as to maintain a constant voltage equal to the cell manufacturer&#39;s minimum discharge voltage of an individual cell across the parallel cells. The gradual increase of the resistance counteracts the reducing current drawn from the cells by the programmable load  22 , while maintaining a constant voltage. The gradual resistance increase may continue until the current has tapered to a predefined current limit. In an embodiment, the current limit may be 0.05C milliamps where C is the one hour discharge rate; however, this limit is in no way intended to be limiting upon the current threshold to be used with described embodiment; rather, the current threshold may comprise any current value based on the number of cells to be discharged and the manufacturer&#39;s characteristics of the cells. Once the current drawn by the adjustable load  22  has been tapered to below the threshold current value, the cells C 1 , C 2 , and C 3  are determined to be fully discharged and the discharge is terminated. The cell characteristics such as remaining capacity and state-of-charge been balanced at point very close to the manufacturer&#39;s recommended discharge voltage. This also produces a cell balance at the critical point of the chemical discharge. The cells C 1 , C 2 , and C 3  may then be charged to their full de-rated capacity. 
         [0035]    De-rating is a process by which a rechargeable battery is charged to a specified voltage below the maximum voltage capacity as recommended by the manufacturer. For example, a battery cell may be charged to 4.2 V as recommended by the manufacturer; however, the de-rated voltage may only 4.1 V. While a de-rated battery experiences some reduced operational life, typically this loss is less than or equal to 10% of the total battery operation life. De-rating the battery improves the number of times a battery can be recharged over the lifetime of the battery and improves the safety considerations of the battery while the battery is being recharged. 
         [0036]    In manufacturing an embodiment of the battery, the plurality of cells may be welded together using conductive straps, which may comprise the metal nickel. Prior to the welding of the nickel straps, the cells may be placed into a cell balancing circuitry, such that the cells are placed in parallel with balancing circuitry and the cells are thus balanced prior to assembly of the battery. Alternatively, the cells may be placed in connection individually with balancing circuitry such that the cells are each placed at substantially the same charge state prior to the assembly of the battery. In a further embodiment a controller  28  is not used and human observation and input is used to control the connection of the battery  26  to the balancing circuitry  20  and the control of the programmable load  22 . 
         [0037]    The medical field utilizes many devices that are desirable in a portable or mobile form. Portable or mobile electronic devices may utilize a battery comprising a plurality of cells as the main power source, or a battery may serve as the back up power source for the operation of these and other electronic devices. Some of these electronic medical devices may be used to monitor the physiological parameters of a patient or may be used to deliver ventilation, nutrition, or other life support. Therefore, a proper power supply is critical to the operation of these medical devices, and the well-being of the patient. Embodiments of the battery as disclosed herein may provide the advantage of enabling a longer battery life between the need for recharging, and may also provide a more accurate estimation of remaining battery charge. Hazardous results may arise if a battery utilizes unbalanced cells and therefore the battery may indicate that charge remains in the battery, while the battery terminates the supply of charge because one of the cells has fallen below the cell discharge minimum voltage threshold. Furthermore, safety standards for medical devices that may utilize a battery as a power source, require that a warning be displayed upon the determination that five minutes of battery charge is remaining in the power source. If the battery terminates the supply of charge prior to the estimated shut down time, this safety standard may not be met. Therefore, by balancing the cells after the discharge of the battery, this safety standard is more reliably achieved and failures to provide an adequate five minute warning may be reduced. 
         [0038]    Embodiments of the presently disclosed battery may comprise the use of lithium ion (Li-Ion) cells in the battery. 
         [0039]    Further embodiments of the described battery may comprise any number of cells and required switches to control the cell configuration as may be necessary for the specific battery design. While all of the present descriptions have utilized a battery comprising three cells and three switches, it is well understood that any number of battery cells may be used in combination within the present disclosure. Furthermore, it is understood and contemplated that as the number of series cells increases, the number of switches would necessarily increase. 
         [0040]    Embodiments of the battery exhibit the advantage of improved battery life and/or charge capacity over other rechargeable batteries as the cell balancing may be performed at either an initial discharge prior to the assembly of the battery, or after every discharge of the battery, before the battery is recharged. 
         [0041]    Embodiments of the battery further provide the advantage of providing an exact balance at a critical point in the battery voltage discharge. The battery discharge voltage discharges at an exponential rate, therefore exacerbating any unbalance in any of the cells as the cells approach the discharge minimum voltage threshold. The balancing circuitry achieves a cell charge balance at the cell manufacturer&#39;s discharge voltage. This allows the cells to evenly discharge in the next operation cycle to evenly discharge through the critical point of the cell chemical discharge. 
         [0042]    Embodiments of the battery further provide the advantage of a more reliable cell discharge such that fewer inadvertent power shut downs are experienced due to cell unbalance, the battery is able to provide a more accurate prediction of remaining battery charge, and the prediction of the remaining battery charge is more accurate at low levels of battery charge, when the prediction is the most important. 
         [0043]    This written description uses examples to disclose features of the embodiments, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 
         [0044]    Various alternatives and embodiments are contemplated as being with in the scope of the following claims, particularly pointing out and distinctly claiming the subject matter regarded as the invention.

Technology Category: 4