Interconnect strip for ultracapacitor module

Abstract

To provide an ultracapacitor module withstanding a wide variety of conditions without sacrificing electrical performance.SOLUTION: A module 100 comprises a first ultracapacitor having a first terminal, a second ultracapacitor having a second terminal, and an interconnect strip 110. The interconnect strip comprises a central section 112 positioned between a first attachment section 116 and a second attachment section 118. The first terminal of the first ultracapacitor is connected to the first attachment section of the interconnect strip by a fastening device 150, and the second terminal of the second ultracapacitor is connected to the second attachment section of the interconnect strip by a fastening device 160. The central section is formed from a flexible conductive material. The flexible conductive material may be in the form of braids 114.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of the filing of U.S. Provisional Patent Application No. 62 / 527,345, filed Jun. 30, 2017, which is hereby incorporated by reference in its entirety.

Background Art

[0002] Electrical energy storage cells are widely used to power electronics, electromechanical, electrochemical, and other useful devices. For example, an electric double - layer ultracapacitor generally uses a pair of polarized electrodes containing carbon particles (e.g., activated carbon) impregnated with a liquid electrolyte. Due to the large effective surface area of the particles and the small spacing between the electrodes, a large capacitance value can be achieved. In certain cases, individual double - layer capacitors can be combined together to form a module with an increased output voltage or an increased energy capacity. The capacitors within the module are generally connected together by busbars welded to the terminals. However, one problem with such modules is that they are relatively sensitive to the vibrational forces that may occur during installation or use. That is, strong vibrational forces can sometimes damage or even break the connections, which can result in insufficient electrical performance. Therefore, there is a current need for ultracapacitor modules that can withstand a variety of conditions without sacrificing electrical performance.

Summary of the Invention

Means for Solving the Problems

[0003] According to one embodiment of the present invention, a module is disclosed that includes a first ultracapacitor having a first terminal, a second ultracapacitor having a second terminal, and an interconnecting strip. The interconnecting strip includes a central section positioned between a first mounting section and a second mounting section. The first terminal of the first ultracapacitor is connected to the first mounting section of the strip, and the second terminal of the second ultracapacitor is connected to the second mounting section of the strip. Further, the central section is formed from a flexible conductive material.

[0004] Other features and aspects of the present invention are described in more detail below. The complete and enabling disclosure of the present invention to those skilled in the art, including the best mode thereof, will be described in more detail in the remainder of this specification with reference to the accompanying drawings.

Brief Description of the Drawings

[0005]

Figure 1

Figure 2

Figure 3

Figure 4

Mode for Carrying Out the Invention

[0006] The repeated use of reference numerals in this specification and the drawings is intended to represent the same or similar configurations or elements of the present invention. Those skilled in the art should understand that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present invention embodied in the exemplary structures.

[0007] Generally speaking, the present invention relates to a module including a first ultracapacitor having a first terminal (e.g., a positive terminal) and a second ultracapacitor having a second terminal (e.g., a positive or negative terminal). The first and second terminals of the ultracapacitors are connected together to an interconnecting strip, and at least a portion of the interconnecting strip is formed from a flexible conductive material. For example, the interconnecting strip typically includes a central section positioned between a first attachment section and a second attachment section disposed at opposite ends of the strip. By selectively controlling the shape of these sections and the manner in which these sections are formed, the central section can be made flexible in that it can deform in one or more directions when a vibrational force is applied. In this way, the module can maintain good electrical properties under a wide variety of conditions.

[0008] Referring to FIG. 3, a particular embodiment of the interconnecting strip 110 is shown in more detail. As shown, the strip 110 includes a central section 112 positioned between a first attachment section 116 and a second attachment section 118. The central section 112 can be made flexible using various techniques well known in the art. For example, in one embodiment, the central section 112 can be formed from a flexible conductive material in the form of one or more wires, braids, coils, sheets, bars, etc. For example, in one embodiment, the flexible conductive material may be in the form of a sheet including one or more thin conductive layers. However, in another embodiment, as shown in FIG. 3, the flexible conductive material may be in the form of a braid 114. Regardless of its form, any of a variety of different conductive materials such as copper, tin, nickel, aluminum, etc., as well as alloys and / or coated metals, may be used. If desired, the conductive material may optionally be insulated using a sheath material.

[0009] In addition to controlling the material and form of the flexible conductive material, the shape of the central section 112 may be further controlled to help provide a desired degree of flexibility. For example, the ratio of the length of the central section 112 (「L1」) to the length of the strip (「L2」) generally falls within a range of about 0.6 to about 0.95, in some embodiments within a range of about 0.7 to about 0.9, and in some embodiments within a range of about 0.75 to about 0.85. The length of the central section 112 can span, for example, from about 50 to about 500 millimeters, in some embodiments from about 70 to about 400 millimeters, and in some embodiments from about 80 to about 300 millimeters, while the length of the entire strip 110 can be from about 60 to about 600 millimeters, in some embodiments from about 80 to about 500 millimeters, and in some embodiments from about 100 to about 400 millimeters. The width 「W」 of the strip can similarly span from about 1 to about 50 millimeters, in some embodiments from about 5 to about 40 millimeters, and in some embodiments from about 10 to about 20 millimeters, while the thickness or height can span from about 0.05 to about 10 millimeters, in some embodiments from about 0.1 to about 8 millimeters, and in some embodiments from about 0.5 to about 5 millimeters.

[0010] The manner in which the interconnect strip 110 is attached to the ultracapacitor may vary as is well known in the art. For example, in one embodiment, the first attachment section 116 defines a first opening 162 and the second attachment section 118 defines a second opening 164. The openings 162 and 164 are generally configured to receive the terminals of different ultracapacitors. Referring to FIGS. 1 - 2, for example, a module 100 is shown that includes a first ultracapacitor 120 and a second ultracapacitor 130 connected together by the attachment sections 116 and 118 of the interconnect strip 110. More particularly, in the illustrated embodiment, the terminals (not shown) of the first ultracapacitor 120 are inserted into the opening 162 and a fastening device It is connected to the strip 110 by 150. Similarly, the terminals (not shown) of the second ultra-capacitor 130 are inserted into the opening 164 and connected to the strip 110 by another fastening device 160 which may be the same as or different from the fastening device 150. Suitable fastening devices can include, for example, nuts, washers, bolts, screws, compression or expansion fittings, etc. If desired, the fastening device can be further joined (e.g., welded, adhesively attached, ultrasonically joined, etc.) to the attachment section to ensure that the strip is firmly connected to the ultra-capacitor. Of course, in alternative embodiments, the fastening device may be omitted and the strip may be connected using other techniques such as welding alone. As is well known in the art, ultra-capacitors can be electrically connected together in series or in parallel depending on the particular desired properties. For example, ultra-capacitors can be electrically connected in series such that the terminal of a particular polarity (e.g., positive) of one ultra-capacitor is connected to the terminal of the opposite polarity (e.g., negative) of another ultra-capacitor. In FIGS. 1-2, for example, the positive terminal can extend from the top 122 of the first ultra-capacitor 120 and the negative terminal can extend from the bottom 132 of the second ultra-capacitor 130.

[0011] The module 100 shown in FIGS. 1-2 includes two ultracapacitors connected together in accordance with the present invention. Of course, it should be understood that the module may include additional ultracapacitors, such as, for example, four or more, in some embodiments six or more, and in some embodiments eight to thirty individual ultracapacitors. The additional ultracapacitors may be connected using interconnecting strips or by other techniques. For example, the interconnecting strip 110 shown in FIG. 3 may further be used to connect the third and fourth ultracapacitors together. In such an embodiment, the negative terminal disposed at the bottom (e.g., not shown) of the first ultracapacitor 120 may be connected to the positive terminal of the third ultracapacitor, and the positive terminal disposed at the top (not shown) of the second ultracapacitor 130 may be connected to the negative terminal of the fourth ultracapacitor. Of course, as will be understood by those skilled in the art, the particular number of ultracapacitors and the manner in which they are connected will depend on the desired electrical properties of the module.

[0012] Any of a variety of different individual ultracapacitors can generally be used in the modules of the present invention. Generally speaking, however, an ultracapacitor includes an electrode assembly and an electrolyte contained within a housing and optionally hermetically sealed. The electrode assembly can include, for example, a first electrode including a first carbonaceous coating (e.g., activated carbon particles) electrically coupled to a first current collector, and a second electrode including a second carbonaceous coating (e.g., activated carbon particles) electrically coupled to a second current collector. If desired, particularly when the ultracapacitor includes a number of energy storage cells, it should be understood that additional current collectors may be used. The current collectors may be formed from the same or different materials. Nevertheless, each current collector is typically formed from a conductive metal such as aluminum, stainless steel, nickel, silver, palladium, etc., and a substrate including these alloys. Aluminum and aluminum alloys are particularly suitable for use in the present invention. The substrate may take the form of a foil, sheet, plate, mesh, etc. The substrate may have a relatively small thickness, for example, less than about 200 micrometers, in some embodiments from about 1 to about 100 micrometers, in some embodiments from about 5 to about 80 micrometers, and in some embodiments from about 10 to about 50 micrometers. Although not necessarily required, the surface of the substrate may optionally be roughened by cleaning, etching, blasting, etc.

[0013] The first and second carbonaceous coatings are also electrically connected to the first and second current collectors, respectively. They may be formed from the same or different types of materials, one or It may include multiple layers, but each of the carbonaceous coatings generally includes at least one layer containing activated particles. For example, in certain embodiments, an activated carbon layer may be positioned directly on the current collector and, optionally, may be the only layer of the carbonaceous coating. Examples of suitable activated carbon particles include, for example, activated carbon based on coconut shells, activated carbon based on petroleum coke, activated carbon based on pitch, activated carbon based on polyvinylidene chloride, activated carbon based on phenolic resin, activated carbon based on polyacrylonitrile, and activated carbon from natural sources such as coal, charcoal, or other natural organic sources.

[0014] In certain embodiments, it is considered desirable to help improve the ionic mobility with respect to a certain type of electrolyte after being subjected to one or more charge-discharge cycles by selectively controlling certain aspects of the activated carbon particles, such as their particle size distribution, surface area, and pore size distribution. For example, at least 50 volume% (D50 size) of the particles may have a size in the range of about 0.01 to about 30 micrometers, in some embodiments about 0.1 to about 20 micrometers, and in some embodiments about 0.5 to about 10 micrometers. Similarly, at least 90 volume% (D90 size) of the particles may have a size in the range of about 2 to about 40 micrometers, in some embodiments about 5 to about 30 micrometers, and in some embodiments about 6 to about 15 micrometers. The BET surface may range from about 900 m 2 / g to about 3,000 m 2 / g, in some embodiments from about 1,000 m 2 / g to about 2,500 m 2 / g, and in some embodiments from about 1,100 m 2 / g to about 1,800 m 2 / g.

[0015] In addition to having a certain size and surface area, the activated carbon particles may have certain pores with a certain size distribution. For example, the amount of pores with a size less than about 2 nanometers (i.e., "micropores") may be about 50 volume % or less of the total pore volume, about 30 volume % or less in some embodiments, and may provide a pore volume of from 0.1 volume % to 15 volume % in some embodiments. Similarly, the amount of pores with a size between about 2 nanometers and about 50 nanometers (i.e., "mesopores") may be from about 20 volume % to about 80 volume %, from about 25 volume % to about 75 volume % in some embodiments, and may be from about 35 volume % to about 65 volume % in some embodiments. Finally, the amount of pores with a size greater than about 50 nanometers (i.e., "macropores") may be from about 1 volume % to about 50 volume %, from about 5 volume % to about 40 volume % in some embodiments, and may be from about 10 volume % to about 35 volume % in some embodiments. The total pore volume of the carbon particles is from about 0.2 cm 3 / g to about 1.5 cm 3 / g, and in some embodiments from about 0.4 cm 3 / g to about 1.0 cm 3 / g, and the median pore width may be about 8 nanometers or less, from about 1 to about 5 nanometers in some embodiments, and from about 2 to about 4 nanometers in some embodiments. The pore diameter and the total pore volume may be measured using nitrogen adsorption and analyzed by the Barrett-Joyner-Halenda ("BJH") technique well known in the art.

[0016] If desired, the binder may be present in the first and / or second carbonaceous coating in an amount of about 60 parts or less per 100 parts of carbon, in some embodiments 40 parts or less, and in some embodiments in an amount of about 1 to about 25 parts. The binder may, for example, constitute about 15 wt% or less of the total weight of the carbonaceous coating, in some embodiments about 10 wt% or less, and in some embodiments about 0.5 wt% to about 5 wt%. Any of a variety of suitable binders can be used for the electrode. For example, water-insoluble organic binders include styrene-butadiene copolymers, polyvinyl acetate homopolymers, vinyl acetate-ethylene copolymers, vinyl acetate-acrylic copolymers, ethylene-vinyl chloride copolymers, ethylene-vinyl chloride-vinyl acetate terpolymers, acrylic polyvinyl chloride polymers, acrylic polymers, nitrile polymers, fluoropolymers such as polytetrafluoroethylene or polyvinylidene fluoride, polyolefins, etc., as well as mixtures thereof, etc., and may be used in certain embodiments Water-insoluble organic binders may also include polysaccharides and their derivatives. In certain embodiments, the polysaccharide is a non-ionic cellulose ether, such as an alkyl cellulose ether (e.g., methyl cellulose and ethyl cellulose); a hydroxyalkyl cellulose ether (e.g., hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl hydroxybutyl cellulose, hydroxyethyl hydroxypropyl cellulose, hydroxyethyl hydroxybutyl cellulose, hydroxyethyl hydroxypropyl cellulose, etc.); an alkyl hydroxyalkyl cellulose ether (e.g., methyl hydroxyethyl cellulose, methyl hydroxypropyl cellulose, ethyl hydroxyethyl cellulose, ethyl hydroxypropyl cellulose, methyl ethyl hydroxyethyl cellulose, and methyl ethyl hydroxypropyl cellulose); a carboxyalkyl cellulose ether (e.g., carboxymethyl cellulose); and the like, as well as any of the aforementioned protonated salts, such as sodium carboxyethyl cellulose.

[0017] Other materials may be used within the activated carbon layer of the first and / or second carbonaceous coating and / or within other layers of the first and / or second carbonaceous coating. For example, in certain embodiments, a conductivity promoter may be used to further increase the conductivity. Exemplary conductivity promoters include, for example, carbon black, graphite (natural or artificial), graphene, carbon nanotubes, nanowires or nanotubes, metal fibers, graphene, and mixtures thereof. Carbon black is particularly suitable. When used, the conductivity promoter typically comprises about 60 parts or less, in some embodiments 40 parts or less, and in some embodiments about 1 to about 25 parts per 100 parts of activated carbon particles in the carbonaceous coating. The conductivity promoter may, for example, comprise about 15 wt% or less, in some embodiments about 10 wt% or less, and in some embodiments about 0.5 wt% to about 5 wt% of the total weight of the carbonaceous coating. The activated carbon particles typically likewise comprise 85 wt% or more, in some embodiments about 90 wt% or more, and in some embodiments about 95 wt% to about 99.5 wt% of the carbonaceous coating.

[0018] Specific techniques for applying the carbonaceous coating to the current collector may vary, such as printing (e.g., rotogravure), spraying, slot-die coating, drop coating, dip coating, etc., as is well known to those skilled in the art. Regardless of the application technique, the resulting electrode is typically dried so that moisture is removed from the coating at a temperature of about 100 °C or higher, in some embodiments about 200 °C or higher, and in some embodiments from about 300 °C to about 500 °C. The electrode may be compressed (e.g., calendared) to optimize the volumetric efficiency of the ultracapacitor. After any optional compression, the thickness of each carbonaceous coating may generally vary based on the desired electrical performance and operating range of the ultracapacitor. However, typically, the thickness of the coating is from about 20 to about 200 micrometers, from 30 to about 150 micrometers, and in some embodiments from about 40 to about 100 micrometers. The coating may be present on one or both sides of the current collector. Nevertheless, the thickness of the entire electrode (including the current collector and any optional carbonaceous coating(s) after compression) is typically in the range of about 20 to about 350 micrometers, in some embodiments in the range of about 30 to about 300 micrometers, and in some embodiments in the range of about 50 to about 250 micrometers.

[0019] The electrode assembly typically also includes a separator positioned between the first electrode and the second electrode. If desired, other separators may further be used in the electrode assembly. For example, one or more separators may be positioned on the first electrode, the second electrode, or both. The separator can help prevent electrical short circuits by electrically isolating one electrode from the other, while still allowing ion transport between the two electrodes. For example, in one embodiment, the separator is a cellulose fiber Materials such as (for example, airlaid paper webs, wet paper webs, etc.), non-woven fiber materials (for example, polyolefin non-woven webs), woven fabrics, films (for example, polyolefin films), etc. may be used. Cellulose fiber materials containing natural fibers, synthetic fibers, etc. are particularly suitable for use in ultracapacitors. Specific examples of cellulose fibers suitable for use as separators can include, for example, hardwood pulp fibers, softwood pulp fibers, rayon fibers, regenerated cellulose fibers, etc. Regardless of the specific material used, the separator typically has a thickness of about 5 to about 150 micrometers, in some embodiments about 10 to about 100 micrometers, and in some embodiments about 20 to about 80 micrometers.

[0020] The manner in which the components of the electrode assembly are combined together may vary as is well known in the art. For example, the electrodes and separator may first be folded, wound up, or otherwise brought into contact together to form the electrode assembly. In certain embodiments, the electrodes, separator, and optional electrolyte may be wound up to form an electrode assembly having a "jelly roll" configuration.

[0021] To form an ultracapacitor, the electrolyte is placed in ionic contact with the first and second electrodes before, during, and / or after the electrodes and separator are combined to form an electrode assembly. The electrolyte generally has a non-aqueous nature and thus contains at least one non-aqueous solvent. To help extend the operating temperature range of the ultracapacitor, typically the non-aqueous solvent has a relatively high boiling temperature, e.g., about 150 °C or higher, in some embodiments about 200 °C or higher, and in some embodiments about 220 °C to about 300 °C. Particularly suitable high-boiling solvents include, for example, cyclic carbonate solvents such as ethylene carbonate, propylene carbonate, butylene carbonate, vinylene carbonate, and the like. Of course, other non-aqueous solvents may be used alone or in combination with the cyclic carbonate solvents. Examples of such solvents include, for example, open-chain carbonates (e.g., dimethyl carbonate, ethyl methyl carbonate, diethyl carbonate, etc.), aliphatic monocarboxylates (e.g., methyl acetate, methyl propionate, etc.), lactone solvents (e.g., butyrolactone, valerolactone, etc.), nitriles (e.g., acetonitrile, glutaronitrile, adiponitrile, methoxyacetonitrile, 3-methoxypropionitrile, etc.), amides (e.g., N,N-dimethylformamide, N,N-diethylacetamide, N-methylpyrrolidinone), alkanes (e.g., nitromethane, nitroethane, etc.), sulfur compounds (e.g., sulfolane, dimethyl sulfoxide, etc.); and the like.

[0022] The electrolyte may contain at least one ionic liquid dissolved in the non-aqueous solvent. The concentration of the ionic liquid can be varied, but typically it is desirable for the ionic liquid to be present at a relatively high concentration. For example, the ionic liquid may be present in an amount of about 0.8 moles per liter (M) or more of the electrolyte, in some embodiments about 1.0 M or more, in some embodiments about 1.2 M or more, and in some embodiments about 1.3 to about 1.8 M.

[0023] Ionic liquids are generally salts having a relatively low melting temperature, for example, about 400 °C or lower, in some embodiments about 350 °C or lower, in some embodiments about 1 °C to about 100 °C, and in some embodiments about 5 °C to about 50 °C. The salt contains a cationic species and a counter ion. The cationic species contains a compound having at least one heteroatom (e.g., nitrogen or phosphorus) as a "cation center". Examples of such heteroatom compounds include, for example, unsubstituted or substituted organic quaternary ammonium compounds, such as ammonium (e.g., trimethylammonium, tetraethylammonium, etc.), pyridinium, pi ridazinium, pyrazinium, pyrimidinium, imidazolium, pyrazolium, oxazolium, triazolium, thiazolium, quinolinium, piperidinium, pyrrolidinium, a quaternary ammonium spiro compound in which two or more rings are connected together by a spiro atom (e.g., carbon, heteroatom, etc.), a quaternary ammonium condensed ring (e.g., quinolinium, isoquinolinium, etc.), and the like. For example, in certain embodiments, the cationic species may be an N-spiro bicyclic compound, such as a symmetric or asymmetric N-spiro bicyclic compound having a cyclic ring. An example of such a compound is the following structure:

[0024] [Chemical formula]

[0025] [wherein m and n are independently numbers from 3 to 7, and in some embodiments are 4 to 5 (e.g., pyrrolidinium or piperidinium)] having.

[0026] Similarly, suitable counterions for cationic species include halogens (e.g., chloride, bromide, iodide, etc.); sulfate or sulfonate (e.g., methyl sulfate, ethyl sulfate, butyl sulfate, hexyl sulfate, octyl sulfate, hydrogen sulfate, methane sulfonate, dodecylbenzene sulfonate, dodecyl sulfate, trifluoromethane sulfonate, heptadecafluorooctane sulfonate, sodium dodecylethoxysulfate, etc.); sulfosuccinate; amide (e.g., dicyanamide); imide (e.g., bis(pentafluoroethyl - sulfonyl)imide, bis(trifluoromethylsulfonyl)imide, bis(trifluoromethyl)imide, etc.); borate (e.g., tetrafluoroborate, tetracyano - borate, bis[oxalato]borate, bis[salicylato]borate, etc.); phosphate or phosphinate (e.g., hexafluorophosphate, diethyl phosphate, bis(pentafluoroethyl)phosphinate, tris(pentafluoroethyl)-trifluorophosphate, tris(nonafluorobutyl)trifluorophosphate, etc.); antimonate (e.g., hexafluoroantimonate); aluminate (e.g., tetrachloroaluminate); fatty acid carboxylate (e.g., oleate, isostearate, pentadecafluorooctanoate, etc.); cyanate; acetate; and the like, as well as any combination of the foregoing can be mentioned.

[0027] Some examples of suitable ionic liquids include, for example, spiro-(1,1’)-bipyrrolidinium tetrafluoroborate, triethylmethylammonium tetrafluoroborate, tetraethylammonium tetrafluoroborate, spiro-(1,1’)-bipyrrolidinium iodide, triethylmethylammonium iodide, tetraethylammonium iodide, methyltriethylammonium tetrafluoroborate, tetrabutylammonium tetrafluoroborate, tetraethylammonium hexafluorophosphate, and the like.

[0028] As described above, the ultracapacitor holds the electrode assembly and the electrolyte and is optionally It also includes a housing hermetically sealed by selection. The nature of the housing may vary as desired. In one embodiment, for example, the housing may include a metal container (a "can") formed from tantalum, niobium, aluminum, nickel, hafnium, titanium, copper, silver, steel (e.g., stainless steel), alloys thereof, composites thereof (e.g., a metal coated with a conductive oxide), and the like. Aluminum is particularly suitable for use in the present invention. The metal container may have any of a variety of different shapes such as cylindrical, D-shaped, etc. A cylindrical container is particularly suitable.

[0029] For example, referring to FIG. 4, one embodiment of a housing that can be used in an ultracapacitor is shown in more detail. In this particular embodiment, the housing includes a metal container 2122 (e.g., a cylindrical can) that defines a base 3000 and an open end 3200. To seal the housing, a lid 2118 is disposed over the open end 3200 and attached (e.g., welded) to the container 2122. The lid 2118 can include a first collector disk 2114, which includes a disk-shaped portion 2134, a stud portion 2136, and a fastener 2138 (e.g., a screw). The collector disk 2114 is aligned with a first end of a hollow core 2160 formed at the center of the electrode assembly 10, and then the stud portion 2136 is inserted into the opening of the core, such that the stud portion 2136 contacts the second current collector 40. In this way, the second current collector 40 is disposed in electrical contact with the lid 2118. The fastener 2138 can further be coupled (e.g., screwed) to a first terminal 2116. The metal container 2122 can similarly include a second collector disk 2120, which includes a disk-shaped portion 2142, a stud portion 2140, and a second terminal 2144. The second collector disk 2120 is aligned with a second end of the hollow core 2160, and then the stud portion 2140 is inserted into the opening of the core, such that the stud portion 2140 contacts the current collector 20. In this way, the first current collector 20 is disposed in electrical contact with the base 3000. After being formed, the terminals 2144 and 2116 can be connected to one or more additional ultracapacitors as described above. For example, the terminal 2144 (e.g., positive) can be connected to the terminal of an opposite polarity (e.g., negative) of a second ultracapacitor, while the terminal 2116 (e.g., negative) can be connected to the terminal of an opposite polarity (e.g., positive) of a third ultracapacitor.

[0030] Although not shown in the figures, the ultracapacitor and the module can also include a balancing circuit. Generally, the balancing circuit is used to prevent current such as leakage current from causing damage to other ultracapacitors due to overvoltage. Such a balance can help adjust the voltages across each ultracapacitor to be substantially the same. The module and the balancing circuit can also include a current control device for controlling the current flowing through the ultracapacitor in response to a signal provided by a feedback loop. In this regard, the balancing circuit is not necessarily limited. As long as the balancing circuit can effectively balance the voltages across the ultracapacitor, the balancing circuit can be used in the module of the present invention. Generally, the balancing circuit is electrically connected to the ultracapacitor. Such an electrical connection is not necessarily limited as long as it enables control and / or adjustment of the voltage of the ultracapacitor. The balancing circuit can include any number of electronic components including active and passive components. The components can include any combination such as transistors, resistors, regulators, attenuators, potentiometers, thermistors, diodes (e.g., Zener diodes), comparators (e.g., voltage comparators), amplifiers (e.g., operational amplifiers), voltage dividers, etc. It should be correctly understood that these electronic components can be configured in any way to effectively balance the circuit. In some cases, the balancing circuit can include additional components such as an alarm (e.g., sound or light such as an LED) to notify the presence of overvoltage. Examples of balancing circuits that may be used include those such as U.S. Patent No. 6,806,686 to Thrap, U.S. Patent No. 7,88 0,449 to Thrap, U.S. Patent Application Publication No. 2003 / 0214267 to Long, and U.S. Patent Application Publication No. 2016 / 0301221 to Kaminsky. Further, any number of balancing circuits may be used. For example, the module can include at least one balancing circuit per ultracapacitor. Alternatively, the module can use at least one balancing circuit for a plurality of ultracapacitors.

[0031] In addition, the balancing circuit may be connected to a heat dissipation component. The heat dissipation component can be present anywhere in the module or the ultracapacitor and need not be limited. For example, it may be present on the circuit. Alternatively, or in addition, the component may be connected to a heat sink such as metal. Such metal used as a heat sink can include a metal casing that at least partially or completely surrounds the module and / or the ultracapacitor. Alternatively, or in addition, the metal used as a heat sink may be another structural component of the module and / or the ultracapacitor. For example, the metal may be a brace or a structural component that surrounds the module and / or the ultracapacitor. Such a brace or structural component can serve a dual function of also providing mechanical stability. Connecting the balancing circuit to the heat dissipation component in this way can enable effective and efficient heat dissipation without degrading the performance of the ultracapacitor or the balancing circuit. Furthermore, any number of heat dissipation components may be used. For example, the module can include at least one heat dissipation component per ultracapacitor. Alternatively, the module can use at least one heat dissipation component for a plurality of ultracapacitors.

[0032] Ultra capacitors and modules containing them can be used to store large amounts of charge. As a result, the modules and ultra capacitors of the present invention can be used in a variety of applications. For example, they can be used in a variety of energy applications including, but not limited to, wind turbines, solar turbines, solar panels, and fuel cells. In addition, they can be used in a variety of transportation applications including, but not limited to, vehicles (e.g., battery-powered electric vehicles, buses, engine starting, hybrid electric vehicles including power and brake recovery systems, etc.), trains and trams (e.g., linear motor cars, line switching, starter systems, etc.), and aerospace (e.g., door actuators, escape shoots, etc.). They also have a variety of industrial applications including, but not limited to, automation (e.g., robotics, etc.), vehicles (e.g., forklifts, cranes, electric carts, etc.). They also have a variety of applications in household appliances (e.g., portable media players, handheld devices, GPS, digital cameras, etc.), computers (e.g., laptop computers, PDAs, etc.), and communication systems. The modules and ultra capacitors can also have a variety of military applications (e.g., motor starting for tanks and submarines, phased array radar antennas, laser power supplies, wireless communication, avionics displays and instrumentation, GPS guidance, etc.), and medical applications (e.g., defibrillators, etc.).

[0033] These and other modifications and variations of the present invention can be implemented by those skilled in the art without departing from the spirit and scope of the present invention. In addition, it should be understood that aspects of the various embodiments may be exchanged, wholly or in part, with each other. Furthermore, those skilled in the art will understand that the foregoing description is merely exemplary and is not intended to limit the present invention as further described in such appended claims.

Claims

1. A first ultracapacitor having a first terminal, A second ultracapacitor having a second terminal, An interconnection strip including a central section positioned between a first mounting section and a second mounting section, wherein the first terminal of the first ultracapacitor is connected to the first mounting section of the strip, and the second terminal of the second ultracapacitor is connected to the second mounting section of the strip, The length of the central section is approximately 50 to approximately 500 millimeters, the length of the interconnecting strip is approximately 60 to approximately 600 millimeters, the width of the interconnecting strip is approximately 1 to approximately 20 millimeters, the thickness of the interconnecting strip is approximately 0.05 to approximately 5 millimeters, and the ratio of the length of the central section to the length of the strip is approximately 0.75 to approximately 0.

85. Furthermore, the central section is formed from a flexible conductive material and comprises interconnecting strips in the form of one or more wires, braids, coils, sheets, and / or bars. Includes, A module in which the first mounting section is welded to the first terminal and the second mounting section is welded to the second terminal.

2. The module according to claim 1, wherein the flexible conductive material is in the form of a coil, a sheet, a bar, or a combination thereof.

3. The module according to claim 1, wherein the flexible conductive material is in the form of a braided fabric.

4. The module according to claim 1, wherein the flexible conductive material includes copper, tin, nickel, aluminum, or a combination thereof.

5. The module according to claim 1, wherein the length of the central section is about 70 to about 400 millimeters, and the length of the strip is about 80 to about 500 millimeters.

6. The module according to claim 1, wherein the width of the strip is approximately 5 to approximately 40 millimeters.

7. The module according to claim 1, wherein the thickness of the strip is approximately 0.1 to approximately 5 millimeters.

8. The module according to claim 1, wherein the first mounting section defines a first opening into which the first terminal is received, and the second mounting section defines a second opening into which the second terminal is received.

9. The module according to claim 8, wherein the fastening device connects the first mounting section to the first terminal and the second mounting section to the second terminal.

10. The module according to claim 1, wherein the first terminal and the second terminal have opposite polarities.

11. The module according to claim 1, wherein the module includes 8 to 30 ultracapacitors.

12. Each of the aforementioned ultracapacitors is An electrode assembly including a first electrode, a second electrode, and a separator positioned between the first electrode and the second electrode, A non-aqueous electrolyte that is in ionic contact with the first electrode and the second electrode, The housing containing the electrode assembly and the electrolyte The module according to claim 1, including the following:

13. The module according to claim 12, wherein the first electrode includes a first current collector electrically coupled to a first carbonaceous coating, and the second electrode includes a second current collector electrically coupled to a second carbonaceous coating.

14. The module according to claim 13, wherein the first current collector and the second current collector each include a substrate containing a conductive metal.

15. The module according to claim 14, wherein the conductive metal is aluminum or an alloy thereof.

16. The module according to claim 13, wherein the first carbonaceous coating, the second carbonaceous coating, or both contain activated carbon particles.

17. The module according to claim 12, wherein the separator includes a cellulose fiber material.

18. The module according to claim 12, wherein the electrode assembly has a jelly roll configuration.

19. The module according to claim 12, wherein the non-aqueous electrolyte contains an ionic liquid dissolved in a non-aqueous solvent, and the ionic liquid contains cationic species and counterions.

20. The module according to claim 19, wherein the non-aqueous solvent comprises propylene carbonate, nitrile, or a combination thereof.

21. The module according to claim 19, wherein the cationic species includes an organic quaternary ammonium compound.

22. The module according to claim 12, wherein the housing includes a container having a base and an open end, a lid disposed adjacent to the open end, and the electrode assembly is positioned within the housing.

23. The module according to claim 22, wherein the container is formed from metal.

24. The module according to claim 22, wherein the container has a cylindrical shape.

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