Super capacitor module with protection structure

Abstract

The utility model discloses a super capacitor module with a protection structure, comprising a super capacitor module which comprises a circuit board and a plurality of super capacitor monomers welded on the circuit board; one end of the hollow circular ring is provided with an annular colloid, the hollow circular ring is pasted on the circuit board through the annular colloid, the two form a first cavity, the super capacitor monomer is located in the first cavity, the gap space of the first cavity is filled with a protective material, and the protective material is flush with the other end of the hollow circular ring and the bottom of the super capacitor monomer; the protective shell is arranged on the outer side of the hollow circular ring, an inner wall clamping position is arranged at one end of the protective shell along the inner wall of the protective shell, and the circuit board is arranged on the inner wall clamping position; and the protective layer is filled at the opening of the circuit board and the protective shell, and the protective layer is positioned in the protective shell. According to the utility model, the electrolyte can be effectively prevented from leaking into the environment to cause some unnecessary damage, and meanwhile, the surrounding environment is prevented from being polluted.

Description

Technical Field

[0001] This utility model belongs to the field of supercapacitor technology and relates to a supercapacitor module with a protective structure. Background Technology

[0002] During the charging and discharging process, ions in the electrolyte undergo reversible adsorption and desorption at the electrode-electrolyte interface, forming an electrical double layer to store energy. Therefore, supercapacitors feature short charging and discharging times, long cycle life, high power density, wide operating temperature range, and are environmentally friendly. They can be widely used in rail transportation, national defense, automotive electronics, and energy storage and power generation.

[0003] Due to the limitations of voltage and capacity of individual supercapacitors, it is difficult to meet users' high voltage requirements, thus hindering high power output. Therefore, it is necessary to connect multiple supercapacitors in series to form a supercapacitor module to achieve high voltage.

[0004] Currently, supercapacitor modules are protected in two ways: one is by directly wrapping them with heat shrink tubing without any other protection methods. This method carries the risk of leakage, whether at the rubber stopper or the aluminum shell explosion-proof valve. The other method is to use an aluminum alloy or plastic shell for protection. This method neither reduces the risk of leakage nor provides shock resistance or impact protection.

[0005] Especially when applied to the military field, the requirements for supercapacitor modules become even more stringent. Therefore, there is an urgent need to provide a supercapacitor module with a protective structure. Summary of the Invention

[0006] One object of this invention is to solve at least the aforementioned problems and / or defects, and to provide at least the advantages described below.

[0007] Another objective of this invention is to provide a supercapacitor module with a protective structure. This supercapacitor module with a protective structure, as described in this invention, not only solves the aforementioned risk of leakage but also provides shock resistance and impact resistance.

[0008] Therefore, the technical solution provided by this utility model is as follows:

[0009] A supercapacitor module with a protective structure includes:

[0010] A supercapacitor module comprising a circuit board and multiple supercapacitor cells connected in series and soldered to the circuit board;

[0011] A hollow ring, which is circular in shape, has an annular colloid at one end. The one end of the hollow ring is attached to the circuit board through the annular colloid, and the two form a first cavity. The supercapacitor cell is located in the first cavity. The gaps in the first cavity are filled with protective material, which is flush with the other end of the hollow ring and the bottom of the supercapacitor cell.

[0012] A protective outer shell, which is cylindrical, is disposed on the outside of the hollow ring. One end of the protective outer shell has an inner wall retainer along its inner wall, and the circuit board is disposed on the inner wall retainer.

[0013] A protective layer is provided, which fills the opening between the circuit board and the protective housing, and seals the supercapacitor module. The protective layer is located inside the protective housing.

[0014] Preferably, in the supercapacitor module with protective structure, the other end of the protective shell has a bottom and a downward-facing surrounding platform is provided thereon. A concave groove is provided in the surrounding platform. The end of the supercapacitor cell is located in the surrounding platform, and a second cavity is formed between the surrounding platform and the supercapacitor module. A solid adsorbent layer is provided in the concave groove.

[0015] Preferably, in the supercapacitor module with protective structure, the circuit board is provided with multiple pads, each supercapacitor cell is soldered to one of the pads, and the multiple supercapacitor cells are connected by circuits.

[0016] Preferably, in the supercapacitor module with protective structure, each supercapacitor cell is provided with an explosion-proof valve at its end. The explosion-proof valve does not contact the surrounding platform, and the protective material does not cover the explosion-proof valve.

[0017] Preferably, in the supercapacitor module with protective structure, the lead wire of the supercapacitor module consists of a positive lead and a negative lead, and the exposed length of the positive lead is greater than the exposed length of the negative lead.

[0018] Preferably, in the supercapacitor module with protective structure, the hollow ring is made of any one or more of the following materials: PP, ABS, PBT, ABS reinforced material, and PBT reinforced material.

[0019] The protective shell is made of one or more of the following materials: plastic, PP, ABS, PBT, ABS reinforced material, and PBT reinforced material.

[0020] The annular colloid is made of silicone, AB glue, or UV glue.

[0021] Preferably, in the supercapacitor module with the protective structure, the material of the solid adsorbent layer is one or more of activated carbon, silica gel, and activated alumina.

[0022] This utility model has at least the following beneficial effects:

[0023] The hollow ring of this invention, infused with protective material, enhances the integrity of the module, providing shock absorption and impact resistance. The protective layer prevents direct exposure of electronic components, offering waterproofing, dustproofing, moisture protection, and protection against toxic gases or liquids, while also improving insulation between electronic components and circuitry. The protective shell and solid adsorbent layer reduce the risk of electrolyte leakage at the explosion-proof valve of the supercapacitor unit. The inner wall locking mechanism acts as a buffer, preventing the supercapacitor module and protective layer from detaching from the protective shell due to improper customer operation.

[0024] Furthermore, the second cavity of this invention is provided with a concave groove, which is circular in shape, and contains a solid adsorbent layer. When all supercapacitor cells experience leakage from their explosion-proof valves, the solid adsorbent layer can effectively adsorb all leaked liquid substances. Considering that in actual product leakage processes, the leaked liquid will not exceed 10% of the total electrolyte volume of the supercapacitor cells, the potential amount of electrolyte leakage is determined, further solidifying the size of the adsorbent powder ingots. Simultaneously, considering the storage space for the powder ingots and the potential amount of liquid leakage, a separate storage space is designed within the casing to encompass both the powder ingots and the leaked liquid.

[0025] For products of different sizes, this utility model features a unique design for internal storage space dimensions that effectively utilizes the internal space structure while ensuring protection.

[0026] The solid adsorbent layer of this invention serves as the first layer of protection, the protective material filled in the first cavity serves as the second layer of protection, and the protective layer serves as the third layer of protection. By employing three layers of protection, the electrolyte can be effectively prevented from leaking into the environment and causing some unnecessary damage, while also preventing pollution of the surrounding environment.

[0027] Other advantages, objectives and features of this invention will be partly apparent from the following description, and partly understood by those skilled in the art through study and practice of this invention. Attached Figure Description

[0028] Figure 1 This is a perspective view of the overall structure in one of the embodiments of this utility model.

[0029] Figure 2This is a schematic diagram of a supercapacitor module in one of the embodiments of this utility model.

[0030] Figure 3 This is a schematic diagram of a hollow ring in one of the embodiments of this utility model.

[0031] Figure 4 This is a schematic diagram of a reinforced supercapacitor module in one embodiment of this utility model.

[0032] Figure 5 This is a schematic diagram of the circuit board structure in one embodiment of this utility model.

[0033] Figure 6 This is a schematic diagram of the protective shell structure in one of the embodiments of this utility model.

[0034] Marking Explanation: 1-Supercapacitor Module; 11-Positive Lead; 12-Negative Lead; 13-Circuit Board; 131-Pad; 132-Circuit Line; 14-Supercapacitor Cell; 15-Explosion-proof Valve; 2-Hollow Ring; 21-Annular Colloid; 3-Protective Shell; 31-Inner Wall Position; 32-Surrounding Platform; 33-Concave Groove; 34-Solid Adsorbent Layer; 4-Protective Layer; 5-First Cavity; 6-Second Cavity. Detailed Implementation

[0035] The present invention will now be described in further detail with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0036] It should be understood that terms such as “having,” “comprising,” and “including” as used herein do not exclude the presence or addition of one or more other elements or combinations thereof.

[0037] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection or setting, a detachable connection or setting, or an integral connection or setting. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances. The terms "lateral," "longitudinal," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0038] like Figures 1 to 6As shown, this utility model provides a supercapacitor module with a protective structure, comprising:

[0039] A supercapacitor module 1 includes a circuit board 13 and a plurality of supercapacitor cells 14 connected in series and soldered to the circuit board 13;

[0040] A hollow ring 2, which is circular in shape, has an annular colloid 21 at one end. The one end of the hollow ring 2 is attached to the circuit board 13 through the annular colloid 21, and the two form a first cavity 5. The supercapacitor cell 14 is located in the first cavity 5. The gaps in the first cavity 5 are filled with protective material, and the protective material is flush with the other end of the hollow ring 2 and the bottom of the supercapacitor cell 14.

[0041] The protective outer shell 3 is cylindrical and is disposed on the outside of the hollow ring 2. One end of the protective outer shell 3 has an inner wall retainer 31 along its inner wall, and the circuit board 13 is disposed on the inner wall retainer 31.

[0042] A protective layer 4 is filled at the opening between the circuit board 13 and the protective housing 3 to seal the supercapacitor module 1. The protective layer 4 is located inside the protective housing 3.

[0043] The hollow ring 2 of this invention incorporates protective material to enhance the integrity of the module, providing shock resistance and impact resistance. The protective layer prevents direct exposure of electronic components, acting as a waterproof, dustproof, moisture-proof, and toxic gas or liquid barrier, while also improving the insulation between electronic components and circuitry. The protective shell 3 reduces the risk of electrolyte leakage at the explosion-proof valve of the supercapacitor unit. The inner wall locking position 31 acts as a buffer, preventing the supercapacitor module and protective layer from detaching from the protective shell due to improper customer operation.

[0044] In one embodiment of this utility model, preferably, the other end of the protective shell 3 has a bottom and a downward-facing surrounding platform 32 is provided thereon. A concave groove 33 is provided in the surrounding platform 32. The end of the supercapacitor cell 14 is located in the surrounding platform 32, and a second cavity 6 is formed between the surrounding platform 32 and the supercapacitor module 1. A solid adsorbent layer 34 is provided in the concave groove 33.

[0045] In one embodiment of this invention, preferably, the circuit board 13 is provided with multiple pads, and each supercapacitor cell 14 is soldered to one of the pads. The multiple supercapacitor cells 14 are connected by circuitry to form a series assembly.

[0046] In one embodiment of this utility model, preferably, each supercapacitor cell 14 is provided with an explosion-proof valve 15 at its end. The explosion-proof valve 15 does not contact the surrounding platform 32, and the protective material does not cover the explosion-proof valve 15.

[0047] In one embodiment of this invention, preferably, the lead wires of the supercapacitor module 1 consist of a positive lead 11 and a negative lead 12, with the exposed length of the positive lead 11 being greater than the exposed length of the negative lead 12. This facilitates user operation.

[0048] To enable those skilled in the art to better understand the technical solution of this utility model, further explanation is provided below:

[0049] This utility model provides a supercapacitor module with a protective structure, which mainly consists of a supercapacitor module 1, a hollow ring 2, a protective shell 3, a protective layer 4, and a solid adsorbent layer 34.

[0050] The supercapacitor module 1 includes supercapacitor cells 14 and a circuit board 13. The internal structure of the supercapacitor cell 14 consists of four parts: an aluminum shell, electrolyte, rubber stopper, and core. Each supercapacitor cell 14 has an explosion-proof valve 15 (either a cross-shaped or Y-shaped valve) at its bottom. The supercapacitor module 1 is formed by soldering five supercapacitor cells 14 onto the circuit board 13. The five supercapacitor cells 14 have relatively fixed positions, determined by the positions of the solder pads 131 on the circuit board. The circuit board 13 is internally connected by copper wires 132 for series connection between the supercapacitor cells 14. The circuit board 13 has five circular solder pads 131, with the diameter of each pad matching the diameter of the supercapacitor cell 14. Each solder pad 131 contains an electronic component and two through holes for lead wires, facilitating soldering. The diameter of the through holes matches the diameter of the positive and negative leads. Soldering of the electronic components and lead wires is done using lead-free solder, making it environmentally friendly. The supercapacitor module 1 has one positive lead 11 and one negative lead 12. The positive lead 11 is longer than the negative lead 12 to facilitate customer differentiation between the positive and negative terminals. All remaining leads are repaired after soldering.

[0051] The hollow ring 2 is a ring of fixed height with a certain thickness of inner wall. An annular colloid 21 is provided along the upper edge of the hollow ring 2. The annular colloid 21 has good viscosity and is made of one of silicone, AB glue, or UV glue. After the supercapacitor module 1 passes performance testing, the annular colloid 21 of the hollow ring 2 is bonded to the circuit board 13 near the supercapacitor cell 14. The hollow ring is made of one or more of PP, ABS, PBT, ABS reinforced, and PBT reinforced materials. The hollow ring 2 and the circuit board 13 form a first cavity 5. Protective material is injected into the first cavity 5 and cured after it is full. During the welding process of the supercapacitor module 1, the roots of the positive electrode lead 11 and the negative electrode lead 12, which are in contact with the colloid plug, cannot completely seal the contact with the circuit board 13, leaving gaps. The protective material can seal the gap between the colloid plug and the circuit board. This prevents electrolyte leakage from the colloid plug during abnormal use of the supercapacitor cell 14, which could then corrode the circuit board 13 and cause losses to the customer. The lower edge of the hollow ring 2, the protective material, and the bottom of the supercapacitor cell 14 are flush, and the protective material cannot cover the explosion-proof valve 15 of the supercapacitor cell 14, forming a reinforced supercapacitor module.

[0052] The protective shell 3 has a cylindrical structure. The bottom of the inner cavity of the protective shell 3 has a concave groove 33 and a surrounding platform 32. Near the upper edge of the inner cavity of the protective shell 3, an inner wall retainer 31 is provided. A solid adsorbent layer 34 is bonded inside the concave groove 33. The solid adsorbent layer 34 is made of one or more of activated carbon, silica gel, and activated alumina. After being processed by an automatic powder molding and ingot-making equipment to form a powder ingot, it is bonded to the bottom of the concave groove 33. The protective shell 3 is made of plastic, specifically one or more of PP, ABS, PBT, ABS reinforced, and PBT reinforced.

[0053] The reinforced supercapacitor module is placed inside the protective housing 3. The circuit board 13 is positioned downwards, passing through the inner wall slot 31 of the protective housing 3 at its lower edge. The positive lead 11 and negative lead 13 are positioned upwards, forming an opening between the circuit board 13 and the protective housing 3. This opening is filled with protective material and cured to form a protective layer 4. The protective layer 4 effectively protects the supercapacitor module 1, providing waterproofing, dustproofing, moisture protection, and protection against toxic gases or liquids, while also improving the insulation between electronic components and circuitry. The inner wall slot 31 acts as a buffer, preventing the supercapacitor module 1 and the protective layer 4 from detaching from the protective housing 3 due to improper customer operation. The surrounding platform 32 must not cover the explosion-proof valve 15 at the bottom of the supercapacitor cell 14, serving a fixing purpose. The height of the protective layer 4 must not exceed the upper edge of the protective housing 3 to prevent the protective material from flowing to the outside of the protective housing 3. Simultaneously, the circuit board 13 must not be exposed to prevent the electronic components from being exposed and causing adverse effects. The protective material is one or more of epoxy resin, polyurethane, and silicone sealant. The lower edge of the reinforced supercapacitor module contacts the surrounding platform 32 of the protective shell 3, forming a second cavity 6. In special circumstances, the explosion-proof valve 15 opens, and the electrolyte leaks from the valve. The solid adsorbent layer 34 adsorbs the electrolyte, preventing the leaked electrolyte from remaining in the second cavity 6 for a long time and corroding the protective shell 3. The supercapacitor with this high-protection structure has the advantages of shock resistance, impact resistance, and leak prevention.

[0054] The second cavity 6 is equipped with a concave groove 33, which is circular. A solid adsorbent layer 34 is placed within the concave groove 33. When all supercapacitor cells 14 experience leakage from the explosion-proof valve 15, the solid adsorbent layer can effectively adsorb all leaked liquid. Considering that in actual product leakage, the leaked liquid will not exceed 10% of the total electrolyte volume of the supercapacitor cells 14, the potential amount of electrolyte leakage is determined, further solidifying the size of the adsorbent powder ingots. Simultaneously, considering the storage space for the powder ingots and the potential amount of liquid leakage, a separate storage space is designed within the casing to encompass both the powder ingots and the leaked liquid.

[0055] For products of different sizes, this utility model features a unique design for internal storage space dimensions that effectively utilizes the internal space structure while ensuring protection.

[0056] The solid adsorbent layer 34 of this invention serves as the first layer of protection, the protective material filled in the first cavity 5 serves as the second layer of protection, and the protective layer 4 serves as the third layer of protection. With these three layers of protection, the electrolyte can be effectively prevented from leaking into the environment and causing unnecessary harm, while also preventing pollution of the surrounding environment.

[0057] The number of modules and processing scale described herein are for the purpose of simplifying the description of this utility model. Applications, modifications, and variations of this utility model will be readily apparent to those skilled in the art.

[0058] Although the embodiments of this utility model have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for this utility model. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, this utility model is not limited to the specific details and the illustrations shown and described herein.

Claims

1. A supercapacitor module with a protective structure, characterized in that, include: A supercapacitor module comprising a circuit board and multiple supercapacitor cells connected in series and soldered to the circuit board; A hollow ring, which is circular in shape, has an annular colloid at one end. The one end of the hollow ring is attached to the circuit board through the annular colloid, and the two form a first cavity. The supercapacitor cell is located in the first cavity. The gaps in the first cavity are filled with protective material, which is flush with the other end of the hollow ring and the bottom of the supercapacitor cell. A protective shell, which is cylindrical, is disposed on the outside of the hollow ring. One end of the protective shell has an inner wall slot along its inner wall, and the circuit board is disposed on the inner wall slot. A protective layer is provided, which fills the opening between the circuit board and the protective housing, and seals the supercapacitor module. The protective layer is located inside the protective housing.

2. The supercapacitor module with a protective structure as described in claim 1, characterized in that, The other end of the protective shell has a bottom and a downward-facing surrounding platform thereon. A concave groove is provided in the surrounding platform. The end of the supercapacitor cell is located in the surrounding platform, and a second cavity is formed between the surrounding platform and the supercapacitor module. A solid adsorbent layer is provided in the concave groove.

3. The supercapacitor module with a protective structure as described in claim 1, characterized in that, The circuit board has multiple pads, and each supercapacitor cell is soldered to one of the pads. The multiple supercapacitor cells are connected by circuits.

4. The supercapacitor module with a protective structure as described in claim 2, characterized in that, Each supercapacitor cell is equipped with an explosion-proof valve at its end.

5. The supercapacitor module with a protective structure as described in claim 1, characterized in that, The lead wires of the supercapacitor module consist of a positive lead and a negative lead, with the exposed length of the positive lead being greater than that of the negative lead.

6. The supercapacitor module with a protective structure as described in claim 1, characterized in that, The hollow ring is made of any one or more of the following materials: PP, ABS, PBT, ABS reinforced material, and PBT reinforced material. The protective shell is made of any one or more of the following materials: plastic, PP, ABS, PBT, ABS reinforced material, and PBT reinforced material. The annular colloid is made of silicone, AB glue, or UV glue.

7. The supercapacitor module with a protective structure as described in claim 2, characterized in that, The solid adsorbent layer is made of one or more of activated carbon, silica gel, and activated alumina.

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