Minit-Charger's Patented Adaptive Charge Control

Minit-Charger's unique and patented charge technology assures higher charge rates for longer periods at typical operating temperatures. This section describes our patented technology in easy to understand terms.

Batteries are recharged by the electrochemical reactions that take place during the charging process. The maximum rate ("battery charge acceptance ability") at which electrical charge energy (charging current) is stored is governed by the slowest component of these reactions. Charge current that exceeds this rate causes detrimental overcharge that negatively affects the life of the battery. Undercharging needlessly lengthens charge time and can result in short term battery capacity decline.

Therefore, it is extremely important to control charger output as close to the battery's charge acceptance ability curve as possible. When done successfully, the result is:

  • Highest battery-safe charge rate
  • Reduced battery heat generation while charging
  • Minimal off-gassing (hence, reduced water consumption)
  • Reduced side reactions which lead to life shortening sulfation on battery plates or tubes
  • Longer useful battery life

And this is where Minit-Charger technology significantly differs from other battery chargers (fast or traditional charge rates). Because the battery's ability to accept maximum charge is a complex variable that varies with use and as the battery ages, Minit-Charger technology uniquely incorporates real time measurement of those parameters so as to identify the battery's ability to accept change. And this input from the battery to the Minit-Charger (via our proprietary BICC or BDC battery modules) is subsequently used to provide real time Minit-Charger output control. Only in this way can a battery be safely charged at the optimum rate for the entire life of the battery.

As a complicating factor, the battery's ability to accept maximum charge will vary with use and as the battery ages, therefore it is imperative to measure these changing parameters that identify the battery's ability to accept change and incorporate that information into real time charger output control.

Minit-Charger's onboard battery modules play the middle man between the battery and the charger. With Minit-Charger's real-time adaptive charge algorithm our battery modules intelligently and continuously determine what happens inside the battery and subsequently instructs the charger to adjust output to maintain the highest safe charge rate - yet still be in compliance with the battery's charge acceptance curve. In other words, the charger becomes a slave to the battery.

Our charge rate is entirely dependent on our patented approach in which the battery is continuously monitored for a variety of data of which the most important is the rate of change of the charge acceptance ability of the battery. In this way, the battery is not unintentionally over- or undercharged. Other parameters, such as battery temperature, are additional supportive measures to ensure safe maximum charge return but are not the basis of control as found in less capable competitor IVI "temperature compensated" fast charger designs. That is why Minit-Charger does not require costly, non-standard air-gapped cells or expensive additions of air cooling fans in lift truck battery compartments as required by our competitors. An added benefit of Minit-Charger technology is that a battery health check is performed at time of vehicle connection to the Minit-Charger. This assures that the conditions of the battery are known prior to initiation of charge.

In contrast, some competitor fast chargers use their battery module primarily to sense battery temperature. Marketing window dressing terms such as "temperature foldback" or "current rollback" - a means by which to reduce charger output - is used by competitors to prevent thermal runaway after the battery has been overcharged. Hence, competitor's methods of charge control are actually only a safety valve. Compare this to Minit-Charger's approach wherein subtle charge current adjustments are constantly and automatically performed throughout the charge period - inclusive of longer term considerations implied by battery aging and recent charging history that may affect battery charge acceptance ability.

So what's the benefit of Minit-Charger's charging technology?

  • Safe optimum charge rates for the life of the battery
  • Proven economic battery life
  • No need for special, extra cost air-gapped battery designs or to control heat in even moderate duty applications
  • No need for lift truck battery cooling fans retrofit
Resources
Read more in the abstract of our most recent Patent 6,495,992 (Dec 2002).