WO2017083711A1

WO2017083711A1 - Systems and methods for electronic desulfation device fabrication, calibration, control, and operation

Info

Publication number: WO2017083711A1
Application number: PCT/US2016/061617
Authority: WO
Inventors: Daniel Charles BIGGS, Jr.
Original assignee: Canadus Power Systems, Llc
Priority date: 2015-11-13
Filing date: 2016-11-11
Publication date: 2017-05-18

Abstract

An electronic desulfation device includes a source of desulfation energy for generating current pulses at a preselected value; a battery sensing system for detecting the condition of a battery connected to the device; and a control for receiving data from the battery sensing system indicative of a condition of the battery, actuating the source of desulfation energy, and in response to a signal external to the electronic desulfation device, setting an operational parameter of the electronic desulfation device.

Description

SYSTEMS AND METHODS FOR ELECTRONIC DE SULFATION DEVICE FABRICATION, CALIBRATION, CONTROL, AND OPERATION

TECHNICAL FIELD

[0001] The present application is directed to electronic desulfation devices and, more particularly, to systems and methods for fabricating, calibrating, controlling, and operating electronic desulfation devices.

BACKGROUND

[0002] Lead-acid batteries generate electricity through a double sulfate chemical reaction. Lead and lead dioxide, the active materials in the plates of a lead-acid battery, react with a sulfuric acid electrolyte to form lead sulfate during battery discharge. The lead sulfate reverts to lead, lead dioxide, and sulfuric acid when the lead-acid battery is recharged. Sulfation is the creation of a stable, crystalline form of lead sulfate that is deposited on the plates of a lead-acid battery and impedes the complete recharging of the battery. Sulfation can result from insufficient charging of lead-acid batteries. Sulfation also may occur gradually as a result of repeated cycles of charging and discharging. Sulfation increases the internal resistance of a lead-acid battery and reduces the normal discharge amount, lengthens the time required to recharge, and increases battery operating temperature. If sufficient sulfation is present in a lead-acid battery, the battery may short circuit.

[0003] Desulfation is the process of reversing the sulfation of a lead-acid battery by removing the crystalline deposits of lead sulfate from the battery plates. Desulfation is effected by providing high-current pulses between the terminals of a lead-acid battery, which is believed to break down sulfate crystals that have formed on the battery plates. Electronic desulfation devices ("EDDs") have been developed that apply pulses of desulfation energy, such as radio frequency energy, to the battery terminals.

[0004] One type of EDD is powered by the lead-acid battery it is connected to desulfate. In that arrangement, the battery powers both the EDD's electronic circuitry and delivers the energy required to desulfate the battery. The EDD's electronic circuitry often requires protection from the environment, and therefore typically is sealed inside an enclosure. Environmental damage can result from vibration, shock, liquid exposure, and/or thermal exposure. Most often, an EDD's electronic circuitry (which may include a printed circuit board ("PCB")) is sealed by placing it into an enclosure and potting it with a material such as silicone or an epoxy potting compound. Maintaining the electronic integrity of the EDD's electronic circuitry during this process is time consuming and costly. Additionally, it is desirable to connect a fuse to the positive cable of the EDD. This fuse is often located near the battery connection point to protect against short circuits originating in the EDD itself or in the cabling leading to the EDD. Such a fuse typically would be placed within a fuse holder. These items and their assembly are time consuming and costly.

[0005] Both assembly of the EDD's electronic circuitry and the fuse have previously been undertaken in a piecewise fashion, requiring manual fabrication of each step. To maintain the integrity of the EDD's electronic circuitry, the sealing process is performed separately from the sealing of the fuse, which is performed separately from the final step of fabricating stress relief sleeves around the exit of each wire from the EDD. And because each of these steps requires time for the plastic/epoxy to cure, additional lag and possible error is introduced to the total fabrication process. If at any point along this series of steps the integrity of the EDD is compromised, then the entire EDD must be scrapped. If, during this multi-step fabrication process, some of the electronic circuitry is disturbed, causing a distortion in the EDD's operating parameters, the EDD may be compromised and must be scrapped.

[0006] The EDD's operating parameters include regulating the pulsating voltage, the pulsating current, the pulsating frequency, and the threshold voltages. These operating parameters, as well as a variety of other functions, are preset or programmed prior to sealing the EDD and are based in those predetermined hardware and/or software configurations. If a single hardware component is out of alignment, either as a result of a disturbance during the fabrication process or because it was originally manufactured outside of its specifications, it may result in a systemic misalignment of the EDD electronic circuitry. Such systemic misalignments (e.g., operating parameters outside of the optimized range) may result in inefficient performance of the battery desulfation process and may affect the electrical system powered by the battery as a whole. Currently, because EDDs are fully encapsulated during the multi-step sealing process, it is not possible to effect any adjustment of the operating parameters of the EDD. Thus, under typical systems and methods for fabricating EDDs , there are EDDs that either are scrapped immediately because they completely fail, or are produced with incurably inefficient operating parameters.

[0007] Accordingly, there is a need for a system and method for fabricating encapsulated EDDs that use a single-step curing process for sealing and stress relief that minimizes disturbance of the electronic circuitry, and post-sealing calibration, control, and operation of EDDs that permit external reprogramming of operating parameters without compromising the sealed nature of the EDD.

SUMMARY

[0008] In one aspect, the disclosed electronic desulfation device includes a source of desulfation energy for generating current pulses at a preselected value; a battery sensing system for detecting the condition of a battery connected to the device; and a control for receiving data from the battery sensing system indicative of a condition of the battery, actuating the source of desulfation energy, and in response to a signal external to the electronic desulfation device, setting an operational parameter of the electronic desulfation device.

[0009] In another aspect, a device for desulfation of a battery includes a pulsing system for generating current pulses at a preselected value and frequency; a battery sensing system for detecting the condition of a battery connected to the device; a control connected to the battery sensing system for receiving a signal from the battery sensing system indicative of a condition of the battery connected to the device, and connected to the pulsing system for actuating the pulsing system; and wherein the control programmed to detect an externally applied signal, and in response, set an operational parameter of the device; and a capsule of a polymer that encloses the pulsing system, the battery sensing system, and the control.

[0010] In yet another aspect, a method of making an encapsulated desulfation device includes placing a desulfation device in a mold, the desulfation device having a pulsing system for generating current pulses at a preselected value, a battery sensing system for detecting the condition of a battery connected to the device, a control connected to the battery sensing system for sensing an output of the battery sensing system, and connected to the pulsing system for actuating the pulsing system, the control programmed to detect an externally applied signal, and in response, set an operational parameter of the device, and a lead having a fuse mounted thereon; closing the mold; injecting a polymer into the mold, whereby the polymer encloses the pulsing system, the battery sensing system, the control, and the fuse in a capsule of polymer; removing the device from the mold after the polymer has solidified; and separating the fuse from a remainder of the capsule of polymer.

[0011] In still another aspect, a method of making an encapsulated desulfation device includes placing a shell having complementary upper and lower elements into a mold; placing a desulfation device in the mold between the upper and lower elements, the desulfation device having a pulsing system for generating current pulses at a preselected value, a battery sensing system for detecting the condition of a battery connected to the device, a control connected to the battery sensing system for sensing an output of the battery sensing system, and connected to the pulsing system for actuating the pulsing system, the control programmed to detect an externally applied signal, and in response, set an operational parameter of the device, and a lead having a fuse mounted thereon; closing the mold, thereby joining the upper and lower elements about the device; injecting a polymer into the mold between the upper and lower elements, whereby the polymer encloses the pulsing system, the battery sensing system, the control, and the fuse in a capsule of polymer; removing the device from the mold after the polymer has solidified; and separating the fuse from a remainder of the capsule of polymer.

[0012] In another aspect, a vehicle includes a battery having a positive terminal and a negative terminal; and a desulfation device connected to the battery, the desulfation device including a pulsing system for generating at least one of current and voltage pulses at a preselected value; a battery sensing system for detecting the condition of the battery; and a control connected to the battery sensing system for sensing an output of the battery sensing system, and connected to the pulsing system for actuating the pulsing system, the control programmed to detect an externally applied signal, and in response, set an operational parameter of the device.

[0013] Examples of vehicles include battery-powered vehicles such scooters, electric bicycles, battery-powered golf carts, utility vehicles, aircraft, and marine vehicles. The vehicle may contain a combustion engine or a fuel cell that utilizes a lead-acid battery, or be powered by the lead-acid battery, or a string of lead-acid batteries. [0014] Other aspects of the disclosed systems and methods for electronic desulfation device fabrication, calibration, control, and operation will be apparent from the following description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic top plan view of a mold used to fabricate an encapsulated electronic desulfation device;

FIG. 2 is a perspective view of a detail of the encapsulated electronic desulfation device made by the mold of FIG. 1, wherein the outer shell is broken away to show the PCB;

FIG. 3 is a plan view of the encapsulated electronic desulfation device of FIG. 2;

FIG. 4 is a flow chart showing the process for molding the encapsulated electronic desulfation device using the mold of FIG. 1;

FIG. 5 is a schematic diagram of an embodiment of the disclosed system for electronic desulfation; and

FIG. 6 is a perspective view of the encapsulated electronic desulfation device in a lower mold half of the mold of FIG. 1.

DETAILED DESCRIPTION

[0015] As shown in FIGS. 1 and 6, the system for fabrication of an electronic desulfation device, generally designated 10, may include a two-piece mold 12 having complementary upper and lower mold halves 14, 16, respectively, in which upper mold half 16 is broken away in FIG. 1 to reveal the lower mold half 14. Mold halves 14, 16 may be substantially identical in shape, but mirror images of one another. Mold halves 14, 16 may be closed to define a PCB void 18, an injection sprue 20 communicating with the PCB void, a fuse void 22, elongate positive and negative lead voids 24, 26, respectively, connecting to a lead strain relief void 28 that, in turn, connects to the PCB void. Inlet and outlet lead voids 30, 32, respectively, may be formed in the mold halves 14, 16. The fuse void 22 may be connected to the PCB void 18 by a fuse runner 34. [0016] In an embodiment, mold halves 14, 16 each may have a recess forming a component of none, one, or more of the PCB void 18, injection sprue 20, fuse void 22, lead voids 24, 26, lead strain relief void 28, inlet and outlet lead voids 30, 32, and fuse runner 34. In alternate embodiments, the mold halves 14, 16 each may have one-half of the aforementioned voids 18-30, sprue 20, and runner 34, or one of the mold halves may have less than one-half, and the other mold half have more than one-half. The two-piece mold 12 may be part of an automated system (not shown) in which the mold halves 14, 16 may be opened and closed by pneumatic or hydraulic means.

[0017] A PCB 36 of an electronic desulfation device, generally designated 38, may be placed in the portion of the PCB void 18 formed by the mold half 14. The PCB 36 may include all of the components of the desulfation system 238 described infra with reference to FIG. 5. The electronic desulfation device 38 may include positive and negative leads 40, 42, respectively, connected to the PCB 36. The positive lead 40 may be placed in the portion of the mold half 14 forming the inlet and outlet voids 30, 32, so that a fuse 44 on the positive lead lies within the fuse void 22.

[0018] In an embodiment, the mold half 16 now may be placed over mold half 14, thereby closing the mold 12 and forming the voids 18, 22, 24, 26, 28, 30, the sprue 20, and runner 34. A molten plastic material, which may be a polymer, from a heated barrel 46 of an injection molding machine 48 may be injected into the PCB void 18 of the mold 12 through the sprue 20. There, the molten plastic material may surround the PCB 36 and fill the PCB void 18. From there, the molten plastic material flows into the strain relief void 28, where it surrounds the positive and negative leads 40, 42, respectively, within the strain relief void 28. Molten plastic material also flows from the PCB void 18 through the runner 34 to surround the fuse 44 and fill the fuse void 22.

[0019] In an embodiment, the aforementioned process may be performed with a single injection stroke by the injection molding machine 48, and takes no more than 3 seconds to fill the voids 18, 22, 25, 26, 28, and 30 formed by the mold halves 14, 16. Once the plastic material has become stable, the mold 12 may be opened by separating mold halves 14, 16 from each other, and the electronic desulfation device 38, in which the fuse 44 and PCB 36 are now encapsulated in a hard plastic, may be removed from the mold. [0020] As shown in FIG. 3, the completed encapsulated electronic desulfation device 38 also may include a molded strain relief 50 that is unitary with the polymer capsule 52 that encloses or encapsulates the PCB 36 (see FIG. 1). Once the encapsulated electronic desulfation device 38 (see also FIG. 6) is removed from the mold 12, the plastic runner 54 connecting the capsule 55 of plastic material that encloses fuse 44 to the capsule 52 may be removed, for example by cutting with a blade. A suitable plastic or polymer may be a polyamide (PA), such as Technomelt PA 678, known as Macromelt OM 678, manufactured by Henkel Corporation of Rocky Hill, Connecticut, although other thermoplastic and thermosetting polymers may be employed. The thickness of the encapsulation layer 52 may be between 0.040"-0.060".

[0021] In another embodiment, the polymer capsule 52 enclosing the PCB 36 may itself be encapsulated in a hard shell, generally designated 56, as shown in FIGS. 1, 2, and 3. As shown best in Fig. 2, the hard shell 56 may include complementary upper and lower shell halves 58, 60, respectively. The shell halves 58, 60 may meet at a peripheral joint 62 that may include a snap fit or interference fit, and/or have elements 64 positioned about the periphery that engage to form a snap fit or interference fit. The shell halves 58, 60 may define an interior space 66 shaped to receive the PCB 36 and the encapsulating polymer 52 (FIG. 1). A light pipe 68, which in embodiments may be integral to, or unitary with, the PCB 36, may extend through opening 70 in upper shell half 58. As described in greater detail with reference to FIG. 6, the light pipe 70 may include a transducer that is connected to transmit a signal, received by the light pipe, to the control 220 of the PCB. The shell halves 58, 60 together may form an opening 72 shaped to provide clearance for the strain relief 50 (FIGS. 1 and 3) and a hole 74 that aligns with the sprue 20 (FIGS. 1 and 2).

[0022] An embodiment of a process for enclosing the encapsulated PCB 36 is set forth in FIG. 4. Initially, as indicated in box 100, the mold 12 may be opened by separating the mold halves 14, 16, and the lower shell half 60 may be placed in the lower portion of the PCB void 18. As indicated in box 102, the PCB 36 may be placed on the lower shell half 60, and, as indicated in box 104, the fuse 44 may be placed in the fuse void 22. As indicated in box 106, the upper shell half 58 may be closed over the PCB 36, forming the shell interior space 66, and the mold 12 may be closed. Molten plastic material may be injected from the injection molding machine 48, through the heated barrel 46 and sprue 20, and into the shell interior space 66, as indicated in box 108, where it surrounds and encloses the the PCB 36.

[0023] From the shell interior space 66, the molten plastic may flow through runner 34 to fuse void 22, where it may encapsulate fuse 44, and through opening 72, where it may form strain relief 50 around positive and negative leads 40, 42. Plastic may be prevented from flowing through the opening 68 by the close fit of the light pipe 70 within it, and from flowing through lead voids 24, 26, 20, 23 by the close fit of the leads 40, 42 within them.

[0024] Once the plastic has stabilized, as indicated in box 110, the mold 12 may be opened by separating halves 14, 16 and the electronic desulfation device 76, now encapsulated within the solidified polymer capsule 52 and hard shell 56, may be removed from the mold half 14. The fuse 44, now encapsulated with the polymer, may be separated from the polymer capsule 52, as indicated in box 112. Suitable materials for the hard shell 56 include a relatively hard thermoplastic polymer material, such as polybutylene terephthalate (PBT), or a glass-reinforced resin, such as VALOX Resin DR48 manufactured by SABIC Global Technologies B.V., Bestolen Vennootschap, Netherlands. In an embodiment, the outer hard shell 56 may itself be injection molded prior to use in the aforementioned process, and plasma treated to promote adhesion to the injected polymer capsule 52. As with the previously described embodiment, the device 76 may be formed by a single injection molding step that takes three seconds, or on the order of a few seconds.

[0025] The encapsulated EDD 76 may be made from any elastomer that is sufficiently heat resistant and suitable for absorbing anticipated vibration and/or shock. The elastomer compositions that are thermally conductive can be used to transfer (i.e., act as a conduit) heat from electronic components to other support structures, heat sinks, or cooling structures and chasses.

[0026] Hereinafter, the term "EDD PCB" shall be used to refer generally to the electronic circuitry of an electronic desulfation device, which may include a PCB, such as PCB 36, as well as other accompanying electronic componentry used to desulfate batteries. Throughout this disclosure, modification of the term "EDD PCB" may be made to refer to specific combinations of hardware and/or software components that may provide a particular functionality in addition to the typical EDD functionality. For example, "an externally reprogrammable EDD PCB."

[0027] As shown in FIG. 5, one embodiment of the disclosed electronic desulfation system, generally designated 238, may provide a highly-efficient, fully-encapsulated, externally programmable desulfation device. The system 238 may include an externally reprogrammable EDD 236 capable of providing desulfation energy, which may take the form of generating current pulses at a preselected value, and may be connected to a battery string 200 having a plurality of discrete lead-acid batteries 202, 204, 206.

[0028] The battery string 200 shown in FIG. 5 may take the form of a single battery having a single pair of positive and negative terminals 208, 210, respectively, or may include a plurality of batteries, such as three discrete batteries 202-206, wherein each battery 202-206 may include a plurality of internal cells connected in series. The term "battery" is used when multiple cells are manufactured as a single unit having a single positive terminal and a single negative terminal that can be connected to a device external to the battery, or to another battery. In some cases, the terms "cell" and "battery" may be used interchangeably. Any number of cells or batteries can be used to provide the desired voltage for the battery string 200. For example, the battery string 200 may consist of a single battery 202, which may have one or more internal cells. Each of the cells in the battery string 200 may be connected in series to define a positive terminal 208 and a negative terminal 210 of the battery string.

[0029] The batteries 202-206 of the battery string 200 may be any appropriate electrochemical cells, particularly rechargeable electro-chemical cells, such as lead-acid batteries, and more particularly the type of lead-acid batteries typically used in a vehicle 212, such as a vehicle whose source of motive power is wholly or partially electricity, which may carry the battery string 200 and the electronic desulfation system 238. The vehicle 212 may be selected from a battery-powered scooter, an electric bicycle, a battery-powered golf cart, and a utility vehicle. The batteries 202-206 of the battery string 200 each may include a positive terminal 214 and a negative terminal 216 and may be connected in series to form a single battery 240. The battery string 200 may include individual cells connected in series, or multiple batteries connected in series through interconnects 218. In one aspect, the batteries 202-206 of the string 200 may be lead-acid cells, such as flooded lead-acid battery cells. The batteries 202-206 may have a cell voltage such that the voltage of the string 200 may be calculated by multiplying the number of cells in batteries 202-206 in the string 200 by the cell voltages. For example, the cell voltage is 2 volts for each cell, and there are 18 cells in the string, the string 200 may have a voltage of 36 volts.

[0030] The EDD 238 may include a control 220 with a maximum operating voltage, a pulsing system that may take the form of a source of desulfation energy 222, which may include a pulsing circuit, a negative lead 224, a positive lead 226, a battery sensing system that may take the form of a voltage sensor 228, and a power supply 230 that may take the form of a DC-to-DC converter for converting battery voltage received from battery string 200 to a voltage, such as 5 volts, that can be used by the control circuitry 220. The sources of desulfation energy 222 may be a typical desulfation device or any other appropriate assemblies or apparatus having circuitry or other appropriate components configured to deliver desulfation energy, possibly high-frequency voltage and current delivered to the associated battery cells in pulses. The source of desulfation energy 222 may generate current pulses at a preselected value and/or frequency. For example, the desulfation device may deliver voltage and current at a rate of about 10 kHz. Various desulfation devices known in the art are described in greater detail in U.S. Patent No. 5,648,714 to Eryou et al.; U.S. Patent No. 7,656,128 to Biggs; and U.S. Patent No. 8, 129,954 to Biggs; the entire contents of each of the foregoing patents is incorporated herein by reference.

[0031] The control 220 may be connected to the power supply 230, the voltage sensor 228, and the source of desulfation energy 222. The power supply 230, the voltage sensor 228, and the source of desulfation energy may be connected to the positive lead 226 and to ground or the negative lead 224. The EDD 238 may derive operating power, as well as pulsation power, from the battery string 200 through positive and negative leads 226, 224, respectively.

[0032] The negative lead 224 of the EDD 238 may be connected to the negative terminal

216 of battery 202 of battery string 200, and the positive lead 226 of the EDD may be connected to the positive terminal of battery 206 of battery string 200. The EDD 238 may include control circuitry 220 adapted to facilitate the generation and communication of desulfation energy, such as radio frequency (RF) energy, to the battery string 200. The control 220 may be selected from a digital circuit, a processor, a control unit (e.g., an electronic control unit), and the like. The control 220 may control the amplitude and/or frequency of the desulfation energy supplied by the EDD 238 to the battery string 200, as well as when the desulfation energy is applied to the battery string. The control 220 may include circuits protecting it against reverse polarity connections and/or other incorrect installation and connection conditions.

[0033] In one example process of the disclosed systems, prior to sealing the EDD 238, the control 220 may be programmed to receive voltage readings from the voltage sensor 228 and to set a trigger voltage at a value calculated, for example, as one-third of any sustained voltage reading within a predetermined trigger setting value, e.g., 37 to 50 volts. Once set, the trigger voltage is that voltage at which the control 220 will permit operation of the pulsing circuit of the source of desulfation energy 222 only within a predetermined or preset range higher or lower than the trigger voltage.

[0034] For example, with a predetermined trigger setting value of 37 to 50 volts, if a sustained voltage reading of 39.6 volts is sensed by the voltage sensor 228, then the trigger voltage (i.e., the battery voltage sensed by the voltage sensor 228 that is read by the control 220, which triggers desulfation pulsation from the source of desulfation energy 222 in the EDD 238) will be set to 13.2 volts (i.e., the quotient of 39.6 volts ÷ 3). Thus, in response to a signal external to the electronic desulfation device 238, namely, the voltage detected by the voltage sensor 228 (i.e., the battery sensing system), the control 220 receives a signal from the battery sensing system, namely, the voltage sensor 228, and in response sets an operational parameter of the desulfation device, namely, the trigger voltage.

[0035] In an embodiment, the system 238 may receive a voltage signal from a voltage source 250 connected to leads 224, 226 that is detected by the voltage sensor 228 and communicated to the control 220. The control 220 detects that the voltage sensed by the voltage sensor 228 is above a predetermined threshold, for example 37 volts, and signals the source of desulfation energy 222 to adjust an operational parameter of the EDD 238, namely, adjusting the battery voltage threshold for triggering the pulsation system. In an embodiment, the battery voltage threshold may be one-third of the sensed voltage. Setting a proper trigger voltage ensures that the EDD 238 does not pulse the battery string 200 when the battery is not in use, does not set the trigger voltage based on normal operating voltage spikes or desulfation spikes themselves, and only operates in its optimal range. [0036] The disclosed system 238 may provide the ability to re-calibrate the trigger voltage of the EDD after the EDD has been completely encapsulated by the process described herein with reference to FIGS. 1-4, without reopening the shell . In an embodiment, the control 220 may be adjusted to modify the trigger voltage by a signal external to the system 238 by sending a voltage signal to the voltage sensor 228 having a sustained voltage within the predetermined trigger setting value transmitted over negative and positive leads 224, 226, respectively. Other methods of both wired and wireless communication may be employed to reprogram the trigger voltage of the EDD 238. For example, in an embodiment, the control 220 may include XI 0 power line carrier (PLC) technology that enables the control to transmit and receive information relating to setting the trigger voltage.

[0037] XI 0 PLC technology is a power line carrier communication protocol that superimposes and transmits a 120 kHz encoded signal over a 60 Hz electrical power line of a type contained within a home. A description of the X10 technology is included in U.S. Patent No. 4,200,862, the disclosure of which is incorporated herein by reference. Utilizing the XI 0 PLC protocol, there are 256 different codes available that allow the control circuitry 220 to receive external reprogramming and recalibration of the trigger voltage of the EDD 238.

[0038] In order to enable external reprogramming of an EDD trigger voltage, in embodiments the EDD is provided with the capability of periodically or continuously receiving data. Any analog or digital communication technology may be used to convey the information to the EDD 238. Such known communication technologies may be implemented using wired and/or non-wired technologies. Non-wired technologies may be selected from radio frequency (RF) signal communications, inductive coupling, radiation (including infrared and visible light), and other technologies. The communication protocol may comprise any known or later-developed unidirectional or bidirectional analog, digital, serial, or packet-based communications protocol, including, for example, RS-232, IP, TCP/IP, GPRS, USB, CAN, SNMP, LIN, WiFi, Zigbee, XI 0, Bluetooth (Bluetooth Special Interest Group), and others. The light pipe 70 (FIGS. 1-3) may be used to communicate a signal external to the electronic desulfation system 238 to the control 220 to signal the control to change an operational parameter of the electronic desulfation system. [0039] The examples of the system and method shown in the drawings and described herein are exemplary of numerous examples that may be made within the scope of the appended claims. Additional examples of the invention may further include elements selected from any one or more of the prior art examples described above as needed to accomplish any desired implementation of the structure and function made available by the invention.

Claims

What is claimed is:

1. An electronic desulfation device, the device comprising:

a source of desulfation energy for generating current pulses at a preselected value; a battery sensing system for detecting the condition of a battery connected to the device; and

a control for receiving data from the battery sensing system indicative of a condition of the battery, actuating the source of desulfation energy, and in response to a signal external to the electronic desulfation device, setting an operational parameter of the electronic desulfation device.

2. The device of claim 1, wherein the operational parameter includes a battery voltage threshold for triggering the pulsing system.

3. The device of claim 1, wherein the externally applied signal is selected from an externally applied voltage above a preset value, a radio frequency signal, inductive coupling, and radiation.

4. The device of claim 3, wherein the control receives the externally applied voltage above a preset value from the battery sensing system.

5. The device of claim 3, wherein the battery sensing system includes a voltage sensor.

6. The device of claim 3, further comprising a light pipe communicating with a transducer, and the transducer is connected to transmit a signal to the control.

7. The device of claim 4, wherein the radiation is selected from infrared radiation and visible light radiation.

8. The device of claim 1, further comprising power supply.

9. The device of claim 8, wherein the power supply includes a DC-to-DC converter that converts battery voltage received from the battery connected to the device a to a voltage that powers the control.

10. A device for desulfation of a battery, the device comprising:

a pulsing system for generating current pulses at a preselected value and frequency; a battery sensing system for detecting the condition of a battery connected to the device;

a control connected to the battery sensing system for receiving a signal from the battery sensing system indicative of a condition of the battery connected to the device, and connected to the pulsing system for actuating the pulsing system; and wherein the control programmed to detect an externally applied signal, and in response, set an operational parameter of the device; and

a capsule of a polymer that encloses the pulsing system, the battery sensing system, and the control.

11. The device of claim 10, further comprising a shell made of a relatively hard thermoplastic polymer material, wherein the shell encloses the capsule.

12. The device of claim 11, wherein the capsule is made of a polyamide (PA), and the shell is made of polybutylene terephthalate (PBT).

13. A method of making an encapsulated desulfation device, the method comprising: placing a desulfation device in a mold, the desulfation device having

a pulsing system for generating current pulses at a preselected value, a battery sensing system for detecting the condition of a battery connected to the device,

a control connected to the battery sensing system for sensing an output of the battery sensing system, and connected to the pulsing system for actuating the pulsing system, the control programmed to detect an externally applied signal, and in response, set an operational parameter of the device, and

a lead having a fuse mounted thereon; closing the mold;

injecting a polymer into the mold, whereby the polymer encloses the pulsing system, the battery sensing system, the control, and the fuse in a capsule of polymer;

removing the device from the mold after the polymer has solidified; and

separating the fuse from a remainder of the capsule of polymer.

14. A method of making an encapsulated desulfation device, the method comprising: placing a shell having complementary upper and lower elements into a mold placing a desulfation device in the mold between the upper and lower elements, the desulfation device having

a lead having a fuse mounted thereon;

closing the mold, thereby joining the upper and lower elements about the device; injecting a polymer into the mold between the upper and lower elements, whereby the polymer encloses the pulsing system, the battery sensing system, the control, and the fuse in a capsule of polymer;

removing the device from the mold after the polymer has solidified; and

separating the fuse from a remainder of the capsule of polymer.

15. A vehicle comprising:

a battery having a positive terminal and a negative terminal; and

a desulfation device connected to the battery, the desulfation device including: a pulsing system for generating at least one of current and voltage pulses at a preselected value;

a battery sensing system for detecting the condition of the battery; and a control connected to the battery sensing system for sensing an output of the battery sensing system, and connected to the pulsing system for actuating the pulsing system, the control programmed to detect an externally applied signal, and in response, set an operational parameter of the device.

16. The vehicle of claim 15, wherein the desulfation device is connected to the positive terminal and the negative terminal of the battery.

17. The vehicle of claim 16, wherein the pulsing system is connected to receive energy from the battery to generate the one of current and voltage pulses.

18. The vehicle of claim 15, wherein the battery is a battery string.

19. The vehicle of claim 15, wherein the vehicle is selected from an automobile, a marine vehicle, and an electric vehicle.

20. The vehicle according to claim 15, wherein the vehicle is selected from a battery- powered scooter, an electric bicycle, a battery-powered golf cart, and a utility vehicle.