WO2019051339A1

WO2019051339A1 - Module for improved battery consumption

Info

Publication number: WO2019051339A1
Application number: PCT/US2018/050120
Authority: WO
Inventors: Brett D'ONOFRIO
Original assignee: Donofrio Brett
Priority date: 2017-09-08
Filing date: 2018-09-08
Publication date: 2019-03-14

Abstract

A module for extending the life of a battery comprises a transistor having a base, an emitter and a collector, a transformer having a primary winding and a secondary winding, the secondary winding being subtractive to the primary winding, a first circuit connecting in series the positive terminal of a battery, the primary winding of the transformer, the collector of the transistor and a load, a second circuit connecting in series the positive terminal the battery, the secondary winding of the transformer, a resistor and the base of the transistor, a third circuit connecting the negative terminal of the battery, the emitter of the transistor and the load, and, a capacitor arranged parallel to the battery.

Description

UNITED STATES NONPROVISIONAL UTILITY PATENT APPLICATION

FOR

MODULE FOR IMPROVED BATTERY CONSUMPTION

Inventors:

Brett D'Onofrio

TITLE OF INVENTION

MODULE FOR IMPROVED BATTERY CONSUMPTION

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Serial No. 62/606,048 filed on 09/08/2017, the contents of which are hereby incorporated in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT Not Applicable

REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC AND INCORPORATION-BY-REFERENCE OF THE MATERIAL

Not Applicable.

COPYRIGHT NOTICE

Not Applicable

BACKGROUND OF THE INVENTION Field of the Invention:

[001] The present invention relates to a module for extending the life of a battery. More particularly, the invention relates to a blocking oscillator that generates a pulsed DC current having a higher voltage than the power supply and a capacitor which regenerates the battery.

Description of the Related Art:

[002] Typical batteries supply the direct current. Over time, as a battery drains, the voltage generated by a battery drops. Once the voltage drops below the voltage required by a particular load, the battery is considered "dead" and is usually discarded. If a particular battery has an initial potential of 3 V and it is applied to a 2 V load, a battery is generally deemed dead when in fact it still has a potential of 1.5 or more volts. Thus, half of the potential of the battery is wasted.

[003] In addition, batteries often supply more voltage to a load than is necessary. An unregulated 3 V battery will supply a 3 V potential to a 2 V load, wasting energy given off as heat. This decreases the life of the battery.

[004] The above-described deficiencies of today's systems are merely intended to provide an overview of some of the problems of conventional systems, and are not intended to be exhaustive. Other problems with the state of the art and corresponding benefits of some of the various non-limiting embodiments may become further apparent upon review of the following detailed description.

[005] In view of the foregoing, it is desirable to provide a means for utilizing substantially all of the voltage of a battery. It is also desirable to attenuate a batteries output based upon the minimum potential required to supply a load.

BRIEF SUMMARY OF THE INVENTION

[006] Disclosed is a battery assist module for improving battery consumption and extending the life of a battery. The module operates a direct current source such as a battery at a frequency and voltage determined by the load, not the direct current source itself. Properly modulating a battery's output increases run time and reduces the rate of performance degradation over run time.

[007] In one embodiment, a battery assist module can be placed between any DC voltage source and load, such as LEDs, motors, or any other devices requiring DC voltage, as well as AC devices upon conversion of the signal. The module assists the battery in providing the required load power, providing a coefficient of performance, output power/input power, greater than 1. The power provided by the battery to the module is limited to the power required by the switching device and switching frequency. The load power is provided by the switched flyback solid state generator. The module is also scalable to large power generators.

[008] In another embodiment, a super capacitor can be used, when charged, to directly operate the Bam with or without a battery or other voltage supplies.

[009] In another embodiment, A module for extending the life of a battery comprises a transistor having a base, an emitter and a collector, a transformer having a primary winding and a secondary winding, the secondary winding being subtractive to the primary winding, a first circuit connecting in series the positive terminal of a battery, the primary winding of the transformer, the collector of the transistor and a load, a second circuit connecting in series the positive terminal the battery, the secondary winding of the transformer, a resistor and the base of the transistor, a third circuit connecting the negative terminal of the battery, the emitter of the transistor and the load, and, a capacitor arranged parallel to the battery.

[0010] The module for extending the life of a battery may have a transformer having a toroidal core. The module for extending the life of a battery may be used with a DC alkaline battery. The primary winding and the secondary winding may have the same number of turns. The primary winding and the secondary winding may not have the same number of terms. The load may be at least one LED.

[0011] In another embodiment, a method of generating a pulsed DC current from a battery, wherein the pulsed DC current has a higher voltage than the steady state DC current comprises providing a module for extending the life of a battery comprising a transistor having a base, an emitter and a collector, a transformer having a primary winding and a secondary winding, the secondary winding being subtractive to the primary winding, a first circuit connecting in series a positive lead, the primary winding of the transformer, the collector of the transistor and a load, a second circuit connecting in series the positive lead the battery, the secondary winding of the transformer, a resistor and the base of the transistor, a third circuit connecting the negative lead, the emitter of the transistor and the load, and a capacitor arranged parallel to the negative and positive leads. The module connects a positive terminal of the battery to the positive lead of the module, and a negative terminal of the battery to the negative lead of the module. The load is powered by the module until the battery is no longer capable of charging the transformer.

[0012] It is therefore an object of the present invention to provide a module for more efficiently utilizing all of the voltage potential of a battery or other DC current source. It is another object of the invention to utilize rather than waste flyback from a transformer.

[0013] These and other objects and advantages of the present invention will become apparent from a reading of the attached specification and appended claims. There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

[0015] Figure 1 is a schematic diagram of a battery including a module for improved battery consumption in accordance with the principles of the invention;

[0016] Figure 2 is a top plan view of a toroidal transformer in accordance with the principles of the invention;

[0017] Figure 3 is a graph showing the relationship of a magnetic field to the winding current of a transformer having high magnetic flux density in accordance with the principles of the invention;

[0018] Figure 4 is a chart showing the wave profile of a DC pulsed current generated by a module for improved battery consumption and accordance with the principles of the invention.

DETAILED DESCRIPTION

[0019] The invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

[0020] The disclosed subject matter is described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the various embodiments of the subject disclosure. It may be evident, however, that the disclosed subject matter may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing the various embodiments herein.

[0021] In addition, the term "or" is intended to mean an inclusive "or" rather than an exclusive "or." That is, unless specified otherwise, or clear from context, "X employs A or B" is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then "X employs A or B" is satisfied under any of the foregoing instances. Moreover, articles "a" and "an" as used in the subject specification and annexed drawings should generally be construed to mean "one or more" unless specified otherwise or clear from context to be directed to a singular form.

[0022] Disclosed is a battery assist module that provides for the interconnection of a load to a DC battery that galvanically isolates the battery from the load. The module also limits the current drawn from the battery to the minimum amount required to generate a pulsed DC current sufficient to power the load. Thus, the load determines the operating voltage and current. The battery assist module contains a transformer, a transistor, a resistor and preferably a capacitor.

[0023] The transformer isolates the load from the battery as a generates and stores voltage that is subsequently applied to the load in a DC pulse. The load current is determined by the load voltage applied.

[0024] The transistor is incorporated into the device and a simple blocking oscillator circuit configuration, acting as a switch. The transistor's collector is connected to the primary winding of the transformer while the transistor's base is connected to the secondary winding of the transformer, which is out of phase with, i.e. subtractive to, the primary winding.

[0025] A capacitor such as a super capacitor can be used to increase the battery runtime. The capacitor may optionally be large enough to store enough energy to run the battery assist module without a battery directly connected to it. The module has a coefficient of performance greater than 1.

[0026] Figure 1 shows a battery assist module 10 in accordance with principles of the invention. Module 10 includes a DC battery 12, a transistor 14, a transformer 16, a load 18 and a capacitor 20. A first circuit 22 connects the positive terminal of the battery 12 to the load 18 through the primary winding 24 of the transformer 16 and the collector 26 of the transistor 14 in series. A second circuit 28 connects the positive terminal of the battery 12 to the base 30 of the transistor 14 through secondary winding 32 of the transformer 16 and a resistor 34. A third circuit 36 connects the negative terminal of the battery 12 to the emitter 38 and the load 18. The third circuit 36 may also optionally be connected to a ground.

[0027] Figure 2 shows a toroidal transformer 50 in accordance with principles of the invention. Any transformer having a high flux density will be suitable for use with the invention. Generally, a transformer having a tororidal core, because of its ability to concentrate the magnetic field, may be preferable. Square cores or other shapes may also be suitable. Transformer 50 has a toroidal core 52, a primary winding 54 and a secondary winding 56. The primary 54 and secondary 56 windings are out of phase, or subtractive. An increasing current through the primary winding 54 generates a magnetic flux through the core 52 that in turn generates a current in the secondary winding 56 in a direction opposite to the direction of the current in primary winding 54. In this embodiment, the primary winding 54 and the secondary winding 56 have the same number of turns. Optionally, the windings may have different numbers of turns.

[0028] The toroidal core 52 is formed from metglas, a ferrite material, specifically type J, or other material having a suitably high magnetic flux density. The high flux density of the transformer allows it to charge and discharge quickly. This in turn allows the transformer to generate a high voltage pulse substantially greater than the voltage of the current used to charge the transformer. Figure 2 shows the high flux density of a suitable square loop soft toroidal transform.

[0029] Capacitor 20 may be a super capacitor having a capacitance of up to 365 or more farads. The capacitor 20 is charged by the flyback from the transformer 16 as it discharges. The capacitor 20 may then be drained back into the DC battery, partially recharging it. Optionally, the capacitor 20 may power the transformer during the subsequent cycle after a discharge. As will be understood by those skilled in the arts, a transformer's flyback current and voltage are generally considered undesirable and detrimental to the circuit. Generally, circuits are designed to counteract, minimize or eliminate flyback. The present invention, however, maximizes the flyback due to the high magnetic flux density core of the transformer. The present invention, and set of attempting to eliminate the flyback, captures and stores it in the capacitor. This prevents damage caused by the flyback and further improves the efficiency of the invention.

[0030] The invention may be used with any DC power source, and is useful with common alkaline batteries. Regular Alkaline batteries are not considered rechargeable. However, the module of the present invention does provide limited rechargeability using a limited charge current.

Example 1

[0031] In one exemplary embodiment, the load was two LED's. The first LED was a Cree XML T6 which requires 3 volts, 3 amps and 9 watts. The second LED was a Cree MTG2, which requires 6 volts, 3 amps and 18 watts. Each LED was switched on as loads independently from each other. The module of the invention was connected to a 1.5 V D cell alkaline battery. The module provided 3 volts at 9 watts for the XML T6 and 6 volts at 18 watts for the MTG2 LED, from a single 1.5 volt alkaline D cell. The run as specified for flashlights is the time between initial brightness and 10 % of initial brightness.

[0032] The coefficient of performance = output/input = 9watts/.098 = 91.8 for the Cree XML T6

[0033] The coefficient of performance = 18/.098 =app. l83 for the Cree MTG2

[0034] Based on these results, the regular 1.5 volt alkaline D cell and a bam will have a run time 10+ days (240 hours) of continuous operation. A standard flashlight with a Cree XML T6 and 3 rechargeable AA lithium batteries will typically last up to 1.5 hours run time.

[0035] The output voltage to the load is a pulsed DC. However, this could be converted into a steady- state DC by placing a diode between the module and the load and a capacitor filter across the load.

Functionality of the Module shown in Figure 1 as used in Example 1:

[0036] The transistor has a base, emitter and collector connection. The circuit is connected similar to any blocking oscillator. The toroid transformer has two equal windings. One winding is connected directly between the transistor collector and the positive terminal of the battery. The second winding is connected the between the positive terminal of the battery and the base current limiting resistor. The base current limiting resistor is connected to the base of the transistor. The sense of the first winding is opposite to the second winding. When the collector current goes in a positive, the base current goes in a negative direction. The load is connected between the transistor collector and the negative terminal of the battery (ground). The capacitor is connected according to polarity between positive and negative terminals of the battery.

[0037] Initially, when the battery is connected to Bam, the base current provided to the transistor will produce a collector current, equal to the base current times the transistor HFE (gain):

Icollector= HFE X Ibase

[0038] This Ibase will switch the transistor On. The value of Icoiiector will be determined by HFE and the base resistor 34. Base resistor 34 is may be variable or fixed. This collector current when the transistor is turned on will charge the primary winding 24 connected to the collector. Because of the sense of the windings, when the collector voltage goes positive, the base voltage will go negative due to the toroid core coupling between the two windings. The negative voltage will turn the transistor Off. This is well known in the art as a blocking oscillator. It will continue to switch between ON and Off automatically when voltage is applied to the module 10 by the battery.

[0039] The load R will determine the switching frequency and applied load voltage. f(frequency)=R/L

[0040] For example: LED(Cree XML T6) approximately = two 120 LEDs R=l ohm L=40xl0^"6. The switching frequency would be 25 kHz (kilohertz). The voltage would be:

V(voltage)= L(coil inductance) x I(load) /t_s(switching time)

L=40xl0^"6

t_s =l/f(frequency)=40xl0^"6

V= 40xl0^"6 x 3 A(amps) /40xl0^"6 =3 volts

[0041] The input was still 1.5 from the battery, which by itself cannot light a 3 amp and 3 volt Cree XML T6 LED. The load connected to the module provides the required power for the load.

[0042] Figure 4 shows the input and output voltages of the module during use with a 1.5 volt D cell. The curve 80 is the input voltage to the module at the battery input connection, and had a maximum voltage of 8.29. The curve 82 is the output voltage applied to the LEDs. Maximim voltage was 11.5, and the frequency was 35.3kHz. The load determines the frequency for a given coil:

Frequency = R(load)/L(inductance)

For example, the load of a Cree XML T6 LED is 3 volts 3 amps. R=E/I : R = 3/3= 1 ohm

L (inductance) = 1.2 x 10^"6 x n =1.2 x 10^"6 x 6 (n = turns = 6)

Freqency = R(l ohm)/43.2 x 10^"6 = Approx. 23 kHz

[0043] The XML T6 is in series with the MTG2 (totaling Approximately 360 LEDs). Powering this combination requires 9 volts and 3 amps at 27watts. The same 1.5 volt battery with the same module supported this load with no modifications. For this load:

Frequency = R (3 ohms)/L(43.2 x 10^"3) = 69.4 kHz

Generated voltage E = L x dl\dt

L = 43.2 x 10^A"6 Henries

dt =l/f = 1/69.4 =14.4 x 10^"6

dl=3

E=43.2xlO^A-6 x 3/14.4 x 10^A-6 = 9 volts(3 xml t6 in series)

[0044] The same 1.5 V battery input and the same module 10 supported the load. The load determined the required power input voltage and current, which is delivered by the module.

[0045] Blocking oscillators are generally utilized to provide a square wave signal from a direct current. As can be seen in Figure 4, the module 10 of the present invention provides a spike waveform that rapidly degrades and slopes moderately at the ends. The high magnetic density flux of the transformer and other components of the module make this type of pulse waveform possible. The module intentionally generates an almost instantaneous spike and rapid drop in order to strengthen the flyback current which makes the module function in the desired fashion.

[0046] Figure 5 shows an alternative embodiment of a module for improving battery consumption 100 in accordance with principles of the invention. The module 100 has a very similar configuration to module 10 in Figure 1. It includes a battery 102 and a parallel capacitor 104 connected to a transformer 106, a transistor 108 and a load 110. In this embodiment, a diode 112 is connected between the collector 114 and the load 110. A capacitor 116 is placed parallel to the load 110. This configuration converts the pulsed DC current into a steady-state DC current for the load 110. This configuration is more suitable for loads that perform better under a steady-state current as opposed to a pulsed current. [0047] Those skilled in the art will appreciate that the invention may be scaled up or down for other applications where a load is supplied a voltage potential that decreases over time, such as with an alkaline battery, or with a voltage that is substantially below the voltage required for a particular desired load. The module allows an operator to continue using a DC battery long after it would otherwise be discarded. It allows the operator to utilize much more of the total voltage potential of a battery.

[0048] Whereas, the present invention has been described in relation to the drawings attached hereto, other and further modifications, apart from those shown or suggested herein, may be made within the spirit and scope of this invention. Those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Descriptions of the embodiments shown in the drawings should not be construed as limiting or defining the ordinary and plain meanings of the terms of the claims unless such is explicitly indicated. The claims should be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Claims

1. A module for extending the life of a battery comprising:

a transistor having a base, an emitter and a collector;

a transformer having a primary winding and a secondary winding, the secondary winding being subtractive to the primary winding;

a first circuit connecting in series the positive terminal of a battery, the primary winding of the transformer, the collector of the transistor and a load;

a second circuit connecting in series the positive terminal the battery, the secondary winding of the transformer, a resistor and the base of the transistor;

a third circuit connecting the negative terminal of the battery, the emitter of the transistor and the load; and,

a capacitor arranged parallel to the battery.

2. The module for extending the life of a battery of claim 1 wherein the transformer has a toroidal core.

3. The module for extending the life of a battery of claim 2 wherein the battery is a DC alkaline battery.

4. The module for extending the life of a battery of claim 3 wherein the primary winding and the secondary winding have the same number of turns.

5. The module for extending the life of a battery of claim 3 wherein the primary winding and the secondary winding do not have the same number of terms.

6. The module for extending the life of the battery of claim 4 wherein the load is at least one LED.

7. A method of generating a pulsed DC current from a battery, wherein the pulsed DC current has a higher voltage than the steady state DC current comprising:

providing a module for extending the life of a battery comprising:

a transistor having a base, an emitter and a collector;

a first circuit connecting in series a positive lead, the primary winding of the transformer, the collector of the transistor and a load, a second circuit connecting in series the positive lead the battery, the secondary winding of the transformer, a resistor and the base of the transistor;

a third circuit connecting the negative lead, the emitter of the transistor and the load; and, a capacitor arranged parallel to the negative and positive leads;

connecting a positive terminal of the battery to the positive lead of the module;

connecting a negative terminal of the battery to the negative lead of the module;

powering the load of the module until the battery is no longer capable of charging the transformer.