Abstract: A contact carrier (10) for a first electrical device comprises a contact body (11) having a top (12), bottom (14), and four sides (16). A protrusion (18) extends from the top (12). First and second pivot protrusions or depressions (22, 23) are located on opposing sides (20, 21) of the contact body (11), and allow the contact body (11) to rotate about the axis (24) of the contact body (11) when the protrusion (18) is engaged by a second electrical device. At least one electrical contact (26) is disposed on a first side (27) of the contact body (11). A flexible circuit board (28) interconnects the electrical contact(s) (26) with the first electrical device and may act to bias the contact body (11) such that the electrical contacts (26) are concealed until protrusion (18) is engaged.

Abstract: A battery charger (10) is provided with a power supply (26) which is energized by a main winding (22) and a bias winding (24) on the secondary side (18) of an input transformer (14). The charger switches a main voltage level provided at a main voltage output (28) according to a pulse width modulation scheme, and has an output section (36) for filtering the switched voltage. A power switch (38) is coupled between the output section and the main voltage output, and is driven by a bias switch (48) coupled between the control terminal (50) of the power switch, and a bias voltage output (30), which provides a bias voltage level that is higher then the main voltage level by a minimum delta.

Abstract: An electrochemical cell 10 includes first and second electrodes 12 and 14 with an electrolyte system 26 disposed therebetween. The electrolyte system includes at least a first and second layer 28 and 30, the second layer 30 being used to absorb an electrolyte active species and to adhere the adjacent layer of electrode material to the electrolyte 26. The electrolyte system further includes a process for packaging and curing the electrolyte after it has been incorporated into a discrete battery device.

Abstract: A modular battery pack (10) is described having several embodiments. In general, the modular battery pack has a battery cell cartridge (12), a circuit cartridge (14), and a housing (16). In conventional battery packs these three elements are combined into one single unit. The invention modularizes these components such that portions may be reused and shared. This results in a more cost effective power system for a portable electrical or electronic device (40) since, once the battery cell or cells (48) have expired, they can be replaced without having to replace the other components, in particular the circuitry.

Abstract: A device (111) for simulating a high battery temperature used in charging a rechargeable cell (101). The device takes advantage of a control signal generated by a voltage control circuit (103) used to disconnect a rechargeable cell (101) from a charging system (105) when a predetermined voltage is reached. The device (111) is generally used with cells having a lithium based chemistry and requiring a different charging regime then nickel chemistry cells. The device (111) is activated by the control signal from control circuit (103) which detects a predetermined voltage from rechargeable cell (101) enabling thermistor (113) to change its state. This change is detected by the charging system (105) which alters its mode of operation from a rapid charging rate to a slower charging rate. The device is retrofitable to existing rechargeable batteries allowing them to be charged using existing charging systems alien to the rechargeable battery.

Abstract: A battery recharge current source 12 provides a recharge current 14 to battery cells 16. Recharge current 14 is in excess of an optimum recharge current level for battery cells 16 and is divided into currents 26 and 28 by variable shunt load 24 as controlled by charge current control circuit 18. Charge current control circuit 18 is comprised of current sense circuit 20 and load control circuit 22. Current sense circuit 20 produces a current sense signal in response to current through battery cells 16. Load control circuit 22 is responsive to the current sense signal and controls variable shunt load 24 as needed to conduct excess current away from the battery cells.

Abstract: A battery charging system includes a battery pack (106) and charger (102). Battery pack (106) includes a selectable magnetic field generator (202) which is activated by radio controller (206) when radio (104) changes states. A Hall-effect switch (204) located in either charger (102) or battery (106) receives the magnetic field and informs charger monitor circuit (128) that radio (104) has changed states. This allows for charger (102) to modify the amount of current being provided to radio (104) via line (129). In a second embodiment, an infrared source (402) and an infrared detector (404) are used in place of selectable magnetic field generator (202) and Hall-effect switch (204).

Abstract: A lockout circuit is provided in a battery pack (10) which blocks charging by incompatible chargers while allowing charging by a compatible charger (12). The battery comprises a battery cell or cells (22), and a switch circuit (24). The switch circuit blocks charge current until a switch disable signal is provided to a switch disable contact (18). The switch circuit provides a one way bypass so that the battery may provide power to a device. To eliminate voltage drop while powering a device, a current sense circuit is provided to detect discharge current, and disable the switch circuit.

Abstract: A battery pack (62) comprises cells (74), and is charged by a charger (64) providing a current level. The charger (64) is a typical nickel-cadmium battery charger providing a first charge current level in excess of an optimum charge current level. The battery pack (62) further comprises a thermal sensing element (76) and an overcurrent charge protection circuit having an overcurrent switch (78), current sense circuit (80), comparator circuit (82), and temperature signal switch (84). If the current level through the cells (74) exceeds the optimum charge current level, the current sense circuit (80) provides a signal to comparator circuit (82) which actuates the temperature signal switch (84), simulating a hot battery pack. The charger (64) then switches to a second charge current level which does not exceed the optimum charge current level.

Abstract: An unwelded battery assembly (32) is fed to a shuttle (36) which moves the unwelded battery assembly (32) to a moveable platform (46) in a raised position. The platform lowers the battery assembly into a nest (44) which rigidly supports the battery assembly. An ultrasonic horn is lowered into contact with the battery assembly and welds the battery cover (16) to the battery housing (14). The welded battery assembly (57) is then raised out of the nest by the moveable platform (46), and is moved to a second stage (48) while another unwelded battery assembly is shuttled to the platform. A central control circuit (49) operates and synchronizes the apparatus.

Abstract: An electrochemical cell (10) including a positive electrode (20), a negative electrode (30) and a low temperature organic, liquid lithium salt electrolyte (40) is provided. The low temperature lithium salt electrolyte includes a central atom selected from the group of aluminum, boron, gallium, indium, or thallium and at least four substituent groups which are organic, alkoxy groups. A unique characteristic of the electrolyte is that it remains liquid at ambient temperatures, as compared to most lithium salt electrolytes which are solid at room temperatures.

Abstract: A battery pack (30) is assembled with a flexible circuit board (38), a first tab (40), and a second tab (42). The flexible circuit board (38) has an exposed area of isolated conductor (46) which is located directly under the intersection of the first tab (40) and the second tab (42), a point where the two are resistance welded together (44). When a weld current is applied at this point (44), the isolated conductor area (46) acts as a current sink such that current flows primarily through the second (lower) tab (42). This method allows both tabs or elements to be of the same or similar thickness and electrical properties, and facilitates automated battery pack assembly.

Abstract: A battery charger (12) is used for recharging a battery pack (10) when the battery pack is placed in a charging pocket (14). The battery pack generates heat upon being recharged, which is collected by a probe (22). The probe senses the temperature and changes in temperature of the battery pack by means of a temperature sensing element disposed (54) therein. The temperature sensing element provides an electrical signal indicative of the temperature of the battery pack to a charging circuit (58). The charging circuit, upon sensing sufficient temperature conditions, modifies the operation of the charger such that only low rate currents are thereafter applied to the battery pack.

Abstract: A battery pack (10) has a charge measurement circuit (12) for estimating the state of charge during use. The charge measurement circuit (12) includes a sense resistor (24), amplifier (26), at least one oscillator (28), counter (30), and a communications circuit (32). The battery pack powers a host device (16), which has a limited number of modes of operation, each mode requiring a different current level. The number of oscillators (28) equals the number of modes of operation of the host device (16). As current is drawn from the battery cells (18), the sense resistor (24) and amplifier (26) act to convert the current to a voltage level. The voltage level is fed to each oscillator (28) present. Each oscillator (28) provides a clock signal at a frequency corresponding to one mode of operation of the host device, and is activated when the voltage level is within a preselected range. The clock signal is fed to a counter (30), which counts at a rate determined by the frequency of the active oscillator (28).

Abstract: A battery pack (10) includes a circuit (14) for assuring that a device (16) connected to the battery pack performs in a manner consistent with design requirements, while not exceeding certain thresholds for safety in volatile environments. The battery pack (10) includes a circuit (14) which matches performance requirements with the overall temperature likely to be generated by the device (16).

Abstract: A battery system (400) for use with portable electronic products which includes protection circuitry for allowing the battery system to be safely recharged in a recharging system. The battery system (400) includes cells (401) and a plurality of controls including and overcharge protection circuit (433) for limiting the amount of current to the cells (401) by a charging network and a thermistor (415) and thermistor control (417) for controlling the state of the thermistor (415) to simulate a high temperature condition allowing the charging network to switch modes and accommodate battery system (400) which does not following the charging regimen provided by charging system.

Abstract: A battery pack (10) having a protruding battery contact (14) is provided with a disconnect switch circuit. The circuit comprises at least one battery cell (22), and a mechanical switch (24) which controls .ang.operation of an electronic switch circuit (36). A latch member (16) is provided for attaching the battery pack to a device to be powered, and is moveable between a first and second position, and is biased by a spring means to the first position. In the first position, the latch member acts on the mechanical switch such that the electronic switch circuit disconnects the battery contact from the battery cell or cells. When the latch member is moved to the second position (17), the circuit operates to connect the battery contact to the battery cell or cells.

Abstract: A battery charging system (200) comprises a battery pack (206) and charger (202). Battery pack 206 includes a thermistor (212) for determining the temperature of battery pack (206) and a zener diode (210)in parallel with the thermistor (212) for informing charger (202) of the current capacity of battery (206) or of another battery parameter. Charger (202) includes a transistor (220) and zener diode (214) for effectively switching between measuring thermistor (212) and zener diode (210) at charger input terminal (224). This effectively reduces the number of battery and charger contacts required to measure two battery parameters as compared to the prior art.