Battery Charger Design (1S):

Key considerations and system design limitations

Miguel Aguirre
October, 2012

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Agenda

• Single Cell Charger Systems

• Input Considerations and Limitations
• Topology Options
– Pros & Cons of Power Path Architecture

• Thermal Issues
• Market Trends Needs vs. Limitations
• Charge Time Optimizer
• Summary and Questions

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Single Cell Systems Overview

• Single Cell
– Most Common Solution for Smartphones (1s) and Tablets (1sXp) today
– Allows for simple, low voltage design on the system (Max Battery Voltage
4.35V on some lithium based chemistries)
– Simple design to charge from a 5V supply as the charger will always
operate in step down mode
– Multiple cells in parallel allow for longer run times due to extra capacity
• This will require a higher charge currents to maintain an acceptable charge time.
Charge current will be a function of the current capability of the adapter.

1s configuration 1sXp configuration

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Input Considerations
• How many input connectors will the
device have?
– Single Input (i.e. Micro-USB, Proprietary
Connector)
– Multiple Inputs (i.e. Micro-USB and Dock
Connector)

• How many input sources will the product

support?
– USB charging only (Max current: 500mA
for USB2.0, 900mA for USB3.0)
– USB charging and/or adapter into single
port
• For Micro-USB port, maximum current Output current change based on input voltage (assume
supported by adapter is 1.8A 90% efficiency and 3.6V Battery)
• USB specifies maximum current of 1.5A
• With a limit on the current, changing the input
voltage allows you to increase your output
current
• USB Power Delivery (USBPD) will allow for
more power available for charge solutions.

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Adapter Power Limits

• Adapter Power Limits Today

– Most Smartphones: 5W – 8W
– Most Popular Tablets: 10W – 15W

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Current Capabilities of Adapters

• Power sources have their limits

– There are situations where the input power source does not have enough
power to supply what the portable device demands
– Becoming increasingly important with the standardization of input
connectors such as the Micro-USB
– Input current limits and Input Voltage Dynamic Power Management (VINDPM)
provide the functions needed to solve this problem

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Voltage Input Dynamic Power Management
(VINDPM)
• Utilizing full capacity of adapter – VIN Dynamic Power Management
(VINDPM)
– Loop continuously monitoring the input voltage to the charger
– Without VINDPM the device can enter a hiccup mode between power up and
“brown-out” condition
– When input voltage drops, device will limit the input current

VIN

UVLO
1V/div

Device hits VINDPM

threshold and input
IIN current is reduced 500mA / div

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Voltage Input Dynamic Power Management
(VINDPM)
• Utilizing full capacity of adapter – VIN Dynamic Power Management
(VINDPM)
– Loop continuously monitoring the input voltage to the charger
– Without VINDPM the device can enter a hiccup mode between power up and
“brown-out” condition
– When input voltage drops, device will limit the input current

VIN

IVIN

VBAT

Programmed Charge Device hits VINDPM

current higher than threshold and input
adapter capability current is reduced
STAT

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Power-path vs. Non Power-path Topologies

• Non Power-Path Topology • Power-Path Topology

ICONVERTER
ISYS
ICHARGE ISYS
System
System Load
Load Converter
Charger
IBAT
Charger

IBAT

• The system voltage is always equal to the

battery voltage
• No system startup for deeply discharged batteries
• ICHARGE is always split between IBAT and ISYS
• ICHARGE must be programmed to the maximum
charge current for the battery cell
• If ISYS > Termination current, then termination will
not occur
• IBAT is reduced for any system load
• Reduced charge current extends charge time.
Safety timers may expire prematurely
• ICONVERTER is set to maximize the current from
the source.
• More available current to system and battery
charging for faster charge time
• IBAT is set independent of ICONVERTER
• For low system loads, ICONVERTER is reduced to
maintain proper charge current
• IBAT is always known by charger
• Accurate termination current
• Safety timer extended when charge current is less than
9
programmed value

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Dynamic Power-Path Management (DPPM)

• Function that monitors the input current, input voltage and output
currents of a Power-Path device and automatically gives priority to the
system when the adapter can not support the system load
• See following example of DPPM function in a linear charger. Same
principle allies for switching chargers. Assume 5W adapter (5V, 1A)
IIN≈1A ISYS=0.5A

IBAT=0.5A

10

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Dynamic Power-Path Management (DPPM)

• Function that monitors the input current, input voltage and output
currents of a Power-Path device and automatically gives priority to the
system when the adapter can not support the system load
• See following example of DPPM function in a linear charger. Same
principle allies for switching chargers. Assume 5W adapter (5V, 1A)
IIN≈1A ISYS=0.8A

IBAT=0.2A

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BMS Deep Dive 2012 TI Confidential – Selective Disclosure

 VINDPM and DPPM working together

VIN Adapter Voltage Falls due

to Adapter Current Limit
5V Adapter
rated for 750mA
Input Current Reduced by VINDPM function
to Prevent Adapter from Crashing
IIN

VSYS

750mA Charging 750mA Charging

IBAT Supplement Mode

1.2A Load Step

ISYS

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Does VINDPM = DPPM?

• No. VINDPM prevents the adapter from hitting a “brown-out” condition.

However, the charger will not know how much current is going to the
system and how much current is going to the battery.
– A charger can have VINDPM and not have Power-path (DPPM)
– Charge current and system current is combined and the charger does not
know how much current is being delivered only to the battery

• DPPM allows the charger to know exactly how much current is going to
the battery.
– With this information, the charger can reduce the charge current and extend
the charging safety timer in the even the system demands higher currents

• Which one is better?

– Both topologies allow to charge the battery. Non DPPM chargers will require
the host to measure exactly how much current goes to the battery for proper
termination 13

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Thermal Regulation and Protection Loops
PLOSS = (VIN – VBAT) * ICHG
Thermal management functions:
• Regulate IC junction temperature by reducing charge
current , AND VIN
• Turn off the charger when IC junction temperature is
excessive
• Slow down the safety timers when the charge current is
reduced by the thermal loop, avoiding a false safety timer
fault ICHG

Common implementations: Tj = 1250C

• The IC junction temperature is regulated to a value just
below the maximum operating junction ICHG_THRM
temperature, 1250C typical
• The charger is turned off when the Charger IC junction
temperature is excessive, 1500C typical Time

BMS Deep Dive 2012 TI Confidential – Selective Disclosure 14

Factors affecting thermal performance (effects on θJA)

Case Study: Thermal Effect of PCB design on θJA

Device Size: 2.1mm x 2mm, WCSP

• High K board (no vias), θJA = 69 C/W

• Using 2x2 vias, θJA = 45.4 C/W

EIA/JESD 51-1 Standard

BMS Deep Dive 2012 TI Confidential – Selective Disclosure 15

Product Thickness and Battery Size: Smartphones

HTC One X: 1800mAh, 8.9mm

Samsung Galaxy S3: 2100mAh, 8.6mm

Samsung Galaxy Note: 2500mAh, 10.1mm

HTC One X Battery → 4.4mm thick

Galaxy S3 Battery → 5mm thick

Galaxy Note Battery → 6mm thick

Programmed Charge Device hits VINDPM
current higher than threshold and input
adapter capability current is reduced

Source: TechInsights Teardowns (web)

BMS Deep Dive 2012 TI Confidential – Selective Disclosure 16

Working around tradeoffs…
• Increasing Battery Size → Larger Charge Current
• Decreasing product thickness → Thinner Inductors → Lower Charge
Currents
• 2A – 3A charge current provides sweet spot of short charge times with
acceptable inductor sizes
– Design for 1.5uH converter stability. Tradeoff between efficiency and
inductor size
– Focus on charge time improvements (i.e. Charge Time Optimizer Feature)

4A Inductor 3A Inductor 2A Inductor

2mm height 1.2mm height 1.0mm height
BMS Deep Dive 2012 TI Confidential – Selective Disclosure 17
Charge Cycle → No CTO

83mV Overlap
Charge current
reduces too early

18

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Charge Time Optimizer in Action – bq2426x

Charge Time Optimizer

Sharp handoff of CC and
CV. Approximately 6mV
overlap – Best in industry

Reduces charge time!

For ITERM = 50mA → Total Charge Time ~4:30 hrs

For ITERM = 250mA → Total Charge Time ~ 3:50 hrs

For ITERM = 500mA (<0.1C) → Total Charge Time ~ 3:10 hrs 19

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Extending Run Time on Power Path Chargers

Only 11 mΩ
Optional External
FET Driver

20

BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Summary

• Charger solutions greater than 3A on smartphones increases the

thickness of the design.
– Thermal management is a problem with charge currents greater than 3A.
Not enough board space to extract the heat generated on the charger.

• Focus on reducing charge times with Charge Time Optimizer on newer

TI chargers (bq2425x, bq2426x)
• Increasing run time by reducing battery discharge path impedance (11
mΩ on bq2426x).

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BMS Deep Dive 2012 TI Confidential – Selective Disclosure

Questions?

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BMS Deep Dive 2012 TI Confidential – Selective Disclosure