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`US010541543B2
`
`c12) United States Patent
`Eaves
`
`US 10,541,543 B2
`(IO) Patent No.:
`(45) Date of Patent:
`Jan.21,2020
`
`3/2012 Eaves
`2012/0075759 Al
`4/2013 Eaves
`2013/0103220 Al
`7/2015 Lowe et al.
`2015/0207318 Al
`7/2015 Eaves
`2015/0215001 Al
`2015/0306973 Al* 10/2015 Gunnerud ........... B60L 11/1861
`320/162
`H02J 3/12
`375/257
`
`2016/0111877 Al*
`
`4/2016 Eaves
`
`2016/0134331 Al
`2017/0214236 Al
`2017 /0229886 Al
`
`5/2016 Eaves
`7/2017 Eaves
`8/2017 Eaves
`
`(54) DIGITAL POWER MULTIPORT BATTERY
`CHARGING SYSTEM
`
`(71) Applicant: VoltServer, Inc., East Greenwich, RI
`(US)
`
`(72)
`
`Inventor: Stephen S. Eaves, Charlestown, RI
`(US)
`
`(73) Assignee: VoltServer, Inc., East Greenwich, RI
`(US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 32 days.
`
`(21) Appl. No.: 15/795,451
`
`(22) Filed:
`
`Oct. 27, 2017
`
`(65)
`
`Prior Publication Data
`
`US 2018/0123360 Al May 3, 2018
`Related U.S. Application Data
`
`OTHER PUBLICATIONS
`
`U.S. Patent and TM Office, International Search Report and Written
`Opinion for PCT/US2017 /058745 (corresponding PCT application)
`( dated Jan. 8, 2018).
`
`* cited by examiner
`
`Primary Examiner - Suresh Memula
`(74) Attorney, Agent, or Firm - Modem Times Legal;
`Robert J. Sayre
`
`(60) Provisional application No. 62/415,111, filed on Oct.
`31, 2016.
`
`(57)
`
`ABSTRACT
`
`(51)
`
`(52)
`
`(58)
`
`(2006.01)
`
`Int. Cl.
`H02J 7100
`U.S. Cl.
`CPC .................................. H02J 710021 (2013.01)
`Field of Classification Search
`CPC ..................................................... H02J 7/0021
`USPC .......................................................... 320/109
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`2004/0130292 Al*
`
`7/2004 Buchanan
`
`2009/0204268 Al
`
`8/2009 Eaves
`
`B60L 11/1811
`320/116
`
`The disclosed charging system has multiple charging ports
`emanating from a central digital power transmitter to charge
`a plurality of battery packs. The system comprises a cen(cid:173)
`tralized bulk power converter to produce a first DC voltage
`and multiple additive power converters. One additive power
`converter is assigned to each charger port. The output of
`each charging port is transmitted in digital power format to
`a receiver local to each battery pack. The receiver converts
`the digital power to conventional analog DC power for
`charging the battery packs. The bulk converter provides the
`majority of the power needed to charge all the battery packs
`simultaneously, while the additive power converters adjust
`for the individual characteristics of each battery pack.
`
`12 Claims, 11 Drawing Sheets
`
`. . . - - - - - , Battery
`2~
`Com 1
`
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`
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`3
`
`Page 1 of 20
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`VOLTSERVER EXHIBIT 1006
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`
`Page 2 of 20
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`U.S. Patent
`
`Jan.21,2020
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`Jan.21,2020
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`Sheet 8 of 11
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`Jan.21,2020
`Jan. 21, 2020
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`Sheet 9 0f 11
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`US 10,541,543 B2
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`

`US 10,541,543 B2
`
`1
`DIGITAL POWER MULTIPORT BATTERY
`CHARGING SYSTEM
`
`RELATED APPLICATION
`
`This application claims the benefit of U.S. Provisional
`Application No. 62/415,111, filed 31 Oct. 2016, the entire
`content of which is incorporated herein by reference.
`
`BACKGROUND
`
`Digital electric power, or digital electricity, can be char(cid:173)
`acterized as any power format in which electrical power is
`distributed in discrete, controllable units of energy. Packet
`energy transfer (PET) is a new type of digital electric power
`protocol disclosed in U.S. Pat. Nos. 8,068,937, 8,781,637
`(Eaves 2012) and U.S. Pub. Pat. Application No. US 2017 I
`0229886 Al.
`The primary discerning factor in a digital power trans(cid:173)
`mission system compared to traditional, analog power sys(cid:173)
`tems is that the electrical energy is separated into discrete
`units; and individual units of energy can be associated with
`analog and/or digital information that can be used for the
`purpose of optimizing safety, efficiency, resiliency, control
`or routing. Since the energy in a PET system is transferred 25
`as discrete quantities, or quanta, it can be referred to as
`"digital power" or "digital electricity".
`As described by Eaves 2012, a source controller and a
`load controller are connected by power transmission lines.
`The source controller of Eaves 2012 periodically isolates 30
`(disconnects) the power transmission lines from the power
`source and analyzes, at a minimum, the voltage character(cid:173)
`istics present at the source controller terminals directly
`before and after the lines are isolated. The time period when
`the power lines are isolated was referred to by Eaves 2012 35
`as the "sample period", and the time period when the source
`is connected is referred to as the "transfer period". The rate
`of rise and decay of the voltage on the lines before, during
`and after the sample period reveal if a fault condition is
`present on the power transmission lines. Measurable faults 40
`include, but are not limited to, a short circuit, high line
`resistance or the presence of an individual who has improp(cid:173)
`erly come in contact with the lines.
`Eaves 2012 also describes digital information that may be
`sent between the source and load controllers over the power 45
`transmission lines to further enhance safety or to provide
`general characteristics of the energy transfer, such as total
`energy or the voltage at the load controller terminals. One
`method for communications on the same digital power
`transmission lines as used for power was further described 50
`and refined in U.S. Pat. No. 9,184,795 (Eaves Communica(cid:173)
`tion Patent).
`One application of a digital power distribution system is
`to safely distribute direct-current (DC) power in digital
`format and at elevated voltage from the source side of the 55
`system to the load side.
`U.S. Pub. Pat Application No. 2016/0134331 Al (Eaves
`Power Elements) describes the packaging of the source side
`components of Eaves 2012, in various configurations, into a
`device referred to as a digital power transmitter.
`U.S. Pat. No. 9,419,436 (Eaves Receiver Patent) describes
`the packaging of various configurations of the load side
`components of Eaves 2012 into a device referred to as a
`digital power receiver.
`In the receiver, the DC power is converted from digital 65
`format back to traditional analog DC format for use in
`commonly available power conditioning circuits. The Eaves
`
`5
`
`2
`Receiver Patent describes the employment of power condi(cid:173)
`tioning circuits, widely known to the industry, to take an
`input voltage and produce a controlled alternating-current
`(AC) or DC output voltage. One example is a conditioner
`that takes a 380V DC input and creates a 12V DC output for
`use in a computer. A power conditioning circuit can also
`convert a DC input to an AC output, as is commonly found
`in uninterruptable power supplies or inverters. In its most
`basic form, a power conditioner is a simple switch that either
`10 allows or inhibits current flow. In another application, which
`is the subject of the present invention, digital power is
`converted in a receiver to be compatible with the voltage and
`current format necessary to charge a battery pack used for
`energy storage. More specifically, the battery pack may be
`15 incorporated into an electric vehicle, such as a warehouse lift
`truck or an electric automobile.
`One aspect of the present invention is that the disclosed
`digital power charger system may manage the charging of
`multiple battery packs simultaneously. The concept of dis-
`20 tributing power to various loads on a priority basis was
`introduced in U.S. Pub. Pat. Application No. 2015/0207318
`Al, titled "Digital Power Network Method and Apparatus"
`(Lowe 2014). Lowe 2014 also introduced the concept of
`Power Control Elements (PCEs) to:
`perform safe transfer of energy under digital power for(cid:173)
`mat;
`convert from analog power to digital power under PET
`protocol, or vice versa;
`convert and/or control voltage and/or current; and/or
`switch power from one PET channel to another PET
`channel within the network.
`Lowe 2014 introduced the concept of power conditioning
`circuits within the PCE to convert and/or control voltage
`and/or current. The Eaves Power Elements invention further
`expanded on the definition of power conditioning circuits,
`including AC-to-DC and DC-to-DC conversion that is rel(cid:173)
`evant to the charging system of the present invention.
`Lowe 2014 is relevant to the present invention not only
`for establishing a framework for routing energy on a priority
`basis to multiple battery pack chargers, but also to introduce
`the concept of power control elements that are further
`incorporated into the digital power transmitter of the Eaves
`Power Elements invention. Thus, the system described
`herein is equipped with components to format the voltage
`and current to charge a battery pack, as well as to prioritize
`the allocation of charging energy to the individual battery
`packs. As described herein, a common bulk power supply in
`the transmitter supplies the minimum charge voltage needed
`for all of the battery packs attached to the system.
`Advantageously, the system can utilize a centralized, high
`power, bulk converter that supplies the majority of the
`charging load for multiple battery packs. The bulk converter
`is supplemented by a lower-power, controllable, additive
`power converter assigned to each charge port. From an
`approximately 20%-90% charge state, many battery chem(cid:173)
`istries, such as lithium-ion, operate in a relatively narrow
`voltage range. The bulk converter provides the voltage
`necessary to support the lower limit of the charge state (e.g.,
`20% ), which constitutes the majority of the power require-
`60 ment. Heretofore, conventional charging systems provided
`dedicated power converters for each battery pack, leaving
`power conversion capability underutilized or "stranded"
`when the battery pack has completed charging. Moreover,
`during charging, the power drawn by the battery starts high
`initially and then continuously tapers down as the charging
`continues, again
`leaving power conversion capability
`stranded. By using a central bulk converter, the power
`
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`

`US 10,541,543 B2
`
`4
`SUMMARY
`
`3
`capability of the converter can be redirected based on the
`demand of multiple battery packs, all of which may be at a
`different state of charge. Although a focus of this specifica(cid:173)
`tions is electric automobiles, the system can be utilized with
`any battery pack-such as would be used in warehouse lift 5
`trucks, aerial vehicles
`(drones), automatically guided
`vehicles or portable batteries for lanterns or battery powered
`tools.
`Conventional charging systems for electric vehicles
`(EVs) are separated into "levels" according to their power
`capability, with a "level 1" charger being the least powerful
`and a "level 3" charger, also referred to as a DC fast charger,
`being the most powerful. EV owners often pay more for fast
`charging versus slower charging. Due to the cost and space
`required for a level 3 charger, it is often impractical for a
`customer that is not interested in paying for a fast charge to
`occupy a level 3 charger. This can result in restrictions to
`access to customers, or manual moving of vehicles between
`faster chargers and slower chargers, as when a vehicle has
`completed the fast portion of the charging profile. As dis(cid:173)
`cussed previously, the situation is exasperated when a new
`customer requires charging and another vehicle owner
`remains plugged in to a level 3 charger after the vehicle no
`longer is consuming energy at a high rate.
`A previous multiport charging system disclosed in U.S.
`Pat. No. 8,810,198 (Nergaard) employs a centralized power
`unit that can switch in one or more internal power converter
`stages to an individual charging port. The connection of the
`power converter stages to a charging port is accomplished 30
`using electro-mechanical or semiconductor switches. If the
`demand from one charging port is higher than others in the
`system, Nergaard offers the advantage of being able to direct
`the combined power from multiple power converter stages
`to the high-demand battery pack. For example, if there are
`three charge ports available but only one battery pack being
`charged, then all three power stages can be dedicated to the
`single battery pack. However, only one battery pack can be
`connected to any power stage to prevent the undesirable
`condition of battery packs being electrically connected to
`one another. A disadvantage of the invention ofNergaard is
`that the power bus structure, the number of power stages and
`the number of power switches reach a high level of com(cid:173)
`plexity and cost after only a few charge ports. In regard to
`power switches, if there are N power stages and M charge
`ports, there is a need for 2xNxM switches. In addition to the
`many switches, an internal power bus with attachments to
`each switch pole is needed for each charge port. Since only
`one power stage can be connected to a battery pack, then at
`least one full power stage must be allocated to each battery 50
`pack attached to the system, despite the fact that the battery
`pack may be demanding very little from the power stage.
`The disadvantage of the many power switches and inter(cid:173)
`nal buses of Nergaard is somewhat overcome in U.S. Pat.
`No. 7,256,516 (Buchanan), where a single AC-DC power
`converter stage is combined with multiple DC-DC power
`converter stages, and where each DC-DC stage is assigned
`to one or more charge ports. However, in the invention of
`Buchanan, the summation of power ratings of the DC-DC
`power stages is greater than the rating of the AC-DC power
`converter stage, resulting in a relatively large and expensive
`charging system because, if only a small number of the
`available charge ports are occupied, then each DC-DC
`converter must be rated to utilize a substantial portion of the
`power made available by the AC-DC power converter in
`order to deliver satisfactory charging performance to each
`port.
`
`A digital power charging system and a method for sup(cid:173)
`plying digital power charging are described herein, where
`various embodiments of the apparatus and methods may
`include some or all of the elements, features and steps
`described below.
`A multi port charging system of this disclosure includes a
`plurality of charging ports, a centralized bulk converter, a
`10 plurality of additive power converters, and a control circuit.
`The charging ports are configured to be coupled to a
`respective battery pack. The centralized bulk converter is
`electrically coupled with the charging ports and is control(cid:173)
`lable to provide a first output voltage selected to provide a
`15 majority of a total charge power required for recharging all
`battery packs attached to the charging ports. Each additive
`power converter is assigned to an individual charging port
`and is controllable to provide a second output voltage that,
`when added to the first output voltage, results in a prede-
`20 termined charge to the charging port to which it is assigned.
`Meanwhile, the control circuit is configured to monitor at
`least the electrical current leaving each charging port to
`control at least the second output voltage of the additive
`power converters to individually control a charging current
`25 to the battery packs attached to the charging ports based on
`an algorithm that optimizes at least one factor selected from
`customer satisfaction, price of electricity, maximizing
`charge rate, available capacity from a power source, and
`battery life.
`In a method for charging a plurality of battery packs, as
`described herein, a centralized bulk converter is controlled
`to provide a first output voltage through a plurality of
`charging ports to respective battery packs coupled with the
`charging ports. The first output voltage is selected to provide
`35 a majority of a total charge power required for recharging all
`battery packs attached to the charging ports. Additive power
`converters, each assigned to an individual charging port, are
`controlled to provide a second output voltage that, when
`added to the first output voltage, results in a predetermined
`40 charge to the charging port to which it is assigned. Further(cid:173)
`more, a control circuit is operated to monitor at least the
`electrical current leaving the charging ports to control at
`least the second output voltage of the additive power con(cid:173)
`verters to individually control a charging current to the
`45 battery packs attached to the charging ports based on an
`algorithm that optimizes at least one factor selected from the
`following factors: customer satisfaction, price of electricity,
`maximizing charge rate, available capacity from a power
`source and battery life.
`As described herein, a single bulk converter can be shared
`over many battery packs and additive power converters
`assigned to each charge port only need to be sized for a
`fraction of the power required by the attached battery pack.
`In contrast to Nergaard, the allocation of power to each
`55 charge port is determined by individual output adjustments
`to the additive power converters, and there is no need for
`expensive switches or a dedicated internal power bus for
`each charge port. In contrast to Buchanan, the summation of
`the ratings of the additive power converters can be made less
`60 than the power rating of the bulk converter, due to the
`innovation of the additive power converters adding only a
`portion of the total charging voltage required by the battery
`pack assigned to each port.
`By providing a digital power link between the transmitter
`65 and receivers, a safe installation can be performed at mini(cid:173)
`mal cost due to the avoidance of high cost labor, hard
`conduit and deep trenching requirements. Overload, ground
`
`Page 14 of 20
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`

`

`US 10,541,543 B2
`
`6
`views; and apostrophes are used to differentiate multiple
`instances of the same or similar items sharing the same
`reference numeral. The drawings are not necessarily to
`scale; instead, an emphasis is placed upon illustrating par-
`ticular principles in the exemplifications discussed below.
`
`DETAILED DESCRIPTION
`
`5
`
`5
`fault and arc fault protection is inherent to digital power
`technology avoiding additional costs for external protection
`devices.
`Finally, digital power technology has embedded control
`capability allowing easy implementation of charge control
`and energy management algorithms to optimize the factors
`of:
`customer satisfaction by optimizing charger access,
`charging time, cost, battery pack life and performance,
`avoiding grid capacity overload and operational modes 10
`that would result in higher costs for electricity, and
`advantageous use of alternative energy sources.
`The distribution of power may also be based on algo(cid:173)
`rithms that take into account: 1) service levels to subscribers
`of the charging system, 2) preferred charging levels to 15
`deliver optimal battery life, battery charging speed, and
`relative levels of charging based on one or more of: a)
`battery chemistry; b) battery charge level at the moment; c)
`environmental conditions, including battery pack and ambi(cid:173)
`ent temperature; and d) shared demand of available charging 20
`power that takes into account the service levels purchased by
`the clients attached to the charging system. For example, a
`premium subscriber may be provided with a faster charge
`versus basic subscribers, and a battery pack from a particular
`vehicle may request to execute a unique charge profile that 25
`is stored in the memory of the battery pack controller and
`communicated to the local charge port to which it is
`attached.
`Specifically, the system can allow the custodians of the
`charger system to implement custom algorithms to achieve
`the above factors and to allow battery pack manufacturers to
`initiate custom charge programs based on information com(cid:173)
`municated to the local charge port.
`As will be described in more detail, below, the need to
`have discrete classes of chargers is somewhat alleviated with
`the system disclosed herein due to its novel ability to achieve
`a wide range of charging rates from all charging ports using
`relatively compact and cost efficient power conversion. The
`multiport architecture of the system allows what was pre(cid:173)
`viously classified as a level 3 charging port to have size,
`weight and cost characteristics similar to a level 2 charging
`port, and allows the port to freely transition across level 1,
`level 2 and level 3 charge rate capabilities.
`
`The foregoing and other features and advantages of
`various aspects of the invention(s) will be apparent from the
`following, more-particular description of various concepts
`and specific embodiments within the broader bounds of the
`invention(s). Various aspects of the subject matter intro(cid:173)
`duced above and discussed in greater detail below may be
`implemented in any of numerous ways, as the subject matter
`is not limited to any particular manner of implementation.
`Examples of specific implementations and applications are
`provided primarily for illustrative purposes.
`Unless otherwise herein defined, used or characterized,
`terms that are used herein (including technical and scientific
`terms) are to be interpreted as having a meaning that is
`consistent with their accepted meaning in the context of the
`relevant art and are not to be interpreted in an idealized or
`overly formal sense unless expressly so defined herein. For
`example, if a particular composition is referenced, the
`composition may be substantially (though not perfectly)
`pure, as practical and imperfect realities may apply; e.g., the
`potential presence of at least trace impurities (e.g., at less
`than 1 or 2%) can be understood as being within the scope
`30 of the description. Likewise, if a particular shape is refer(cid:173)
`enced, the shape is intended to include imperfect variations
`from ideal shapes, e.g., due to manufacturing tolerances.
`Percentages or concentrations expressed herein can be in
`terms of weight or volume. Processes, procedures and
`35 phenomena described below can occur at ambient pressure
`(e.g., about 50-120 kPa-for example, about 90-110 kPa)
`and temperature (e.g., -20 to 50° C.-for example, about
`10-35° C.) unless otherwise specified.
`Although the terms, first, second, third, etc., may be used
`40 herein to describe various elements, these elements are not
`to be limited by these terms. These terms are simply used to
`distinguish one element from another. Thus, a first element,
`discussed below, could be termed a second element without
`departing from the teachings of the exemplary embodi-
`45 ments.
`Spatially relative terms, such as "above," "below," "left,"
`"right," "in front," "behind," and the like, may be used
`herein for ease of description to describe the relationship of
`one element to another element, as illustrated in the figures.
`50 It will be understood that the spatially relative terms, as well
`as the illustrated configurations, are intended to encompass
`different orientations of the apparatus in use or operation in
`addition to the orientations described herein and depicted in
`the figures. For example, if the apparatus in the figures is
`55 turned over, elements described as "below" or "beneath"
`other elements or features would then be oriented "above"
`the other elements or features. Thus, the exemplary term,
`"above," may encompass both an orientation of above and
`below. The apparatus may be otherwise oriented (e.g.,
`rotated 90 degrees or at other orientations) and the spatially
`relative descriptors used herein interpreted accordingly.
`Further still, in this disclosure, when an element is
`referred to as being "on," "connected to," "coupled to," "in
`contact with," etc., another element, it may be directly on,
`65 connected to, coupled to, or in contact with the other element
`or intervening elements may be present unless otherwise
`specified.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a block diagram of a digital power charging
`system.
`FIG. 2 is a graph showing a representative charging
`voltage profile of a battery pack.
`FIG. 3 is a graph showing a representative charging power
`profile of a battery pack.
`FIG. 4 is an internal block diagram of a digital power
`transmitter.
`FIG. 5 is a block diagram of a power control element.
`FIG. 6 is a block diagram of a power conditioner for use
`inside a digital power transmitter.
`FIG. 7 is a block diagram of a digital power receiver.
`FIG. 8 is a block diagram of a receiver circuit.
`FIG. 9 shows the charging power profile of two batteries 60
`of varying capacity.
`FIG. 10 is a block diagram of a power conditioner without
`an internal power converter.
`FIG. 11 is a block diagram of a power conditioner
`containing an internal power converter.
`In the accompanying drawings, like reference characters
`refer to the same or similar parts throughout the different
`
`Page 15 of 20
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`

`US 10,541,543 B2
`
`7
`The terminology used herein is for the purpose of describ(cid:173)
`ing particular embodiments and is not intended to be limit(cid:173)
`ing of exemplary embodiments. As used herein, singular
`forms, such as "a" and "an," are intended to include the
`plural forms as well, unless the context indicates otherwise.
`Additionally, the terms, "includes," "including," "com(cid:173)
`prises" and "comprising," specify the presence of the stated
`elements or steps but do not preclude the presence or
`addition of one or more other elements or steps.
`Additionally, the various components identified herein
`can be provided in an assembled and finished form; or some
`or all of the components can be packaged together and
`marketed as a kit w