Modular Ultracapacitor Energy Storage System Design

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Solution Overview

Problem

There is a need for efficient energy storage and charging solutions that can supplement or replace battery-based systems, particularly in applications requiring high power density, rapid charge/discharge cycles, and long operational life, which ultracapacitors can address due to their superior power density, charge/discharge rates, and chemical stability compared to batteries.

Innovation Solution

A modular integrated ultracapacitor (UCAP) electric energy storage and charging apparatus comprising high-capacity UCAP cells electrically coupled in series or parallel configurations, with a power conversion device capable of charging using AC or DC power sources, and conductive hardware for safe and efficient power routing and module connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If batteries are used for energy storage, then energy density is improved, but power density deteriorates

Engineering Contradiction:
Improveenergy densityVSAvoidpower density
Core Design Contradiction:
Use of energy by moving objectVSPower

Solution Approach 1:

The system divides the energy storage function into two separate components: batteries for energy storage and ultracapacitors for power delivery. This segmentation allows each component to optimize its specific function without compromise, with the battery providing high energy density and the ultracapacitor providing high power density.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent combines batteries and ultracapacitors into a hybrid energy storage system where both components work together. The battery and ultracapacitor are electrically connected through a power conversion device, creating a unified system that leverages the complementary strengths of both technologies.

Inventive Principle:
Principle #5Merging (Combining)

2Quantity of substance

If batteries are used for energy storage, then energy storage capacity is improved, but charge/discharge rate deteriorates

Engineering Contradiction:
Improveenergy storage capacityVSAvoidcharge/discharge rate
Core Design Contradiction:
Quantity of substanceVSSpeed

Solution Approach 1:

The system separates the energy storage function (battery) from the rapid charge/discharge function (ultracapacitor). The ultracapacitor module handles high-rate charging and discharging operations, while the battery provides sustained energy storage capacity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

A power conversion device acts as an intermediary between the battery and ultracapacitor, managing power flow and coordinating charge/discharge operations. This intermediary enables the ultracapacitor to absorb or deliver rapid power changes while the battery provides stable energy storage.

Inventive Principle:
Principle #24Intermediary (Mediator)

3Power

If conventional capacitors are used, then power density is improved, but energy density deteriorates

Engineering Contradiction:
Improvepower densityVSAvoidenergy density
Core Design Contradiction:
PowerVSUse of energy by moving object

Solution Approach 1:

The system merges conventional capacitors (ultracapacitors) with batteries in a hybrid configuration. The ultracapacitor provides high power density for burst applications, while the battery supplies high energy density for sustained operation, creating a complementary partnership.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The system dynamically switches between battery and ultracapacitor based on power demands. The control system monitors load requirements and automatically directs power flow to the appropriate source, optimizing performance for varying operational conditions.

Inventive Principle:
Principle #15Dynamics

4Power

If ultracapacitors are used for power delivery, then power density is improved, but energy storage capacity deteriorates

Engineering Contradiction:
Improvepower densityVSAvoidenergy storage capacity
Core Design Contradiction:
PowerVSQuantity of substance

Solution Approach 1:

The system segments the power delivery function from the energy storage function. The ultracapacitor module is dedicated to providing high-power bursts, while the battery module handles sustained energy storage, eliminating the need for the ultracapacitor to compensate for limited energy capacity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The hybrid system serves multiple functions: the battery provides long-term energy storage, the ultracapacitor delivers high-power bursts, and together they provide comprehensive energy management for diverse application requirements.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The modular UCAP system provides scalable, efficient energy storage and power delivery with reduced life-cycle costs, high reliability, and environmental friendliness, capable of replacing batteries in various applications by offering flexible configuration options and compatibility with multiple power sources.

Implementation Method 1

UCAPs store energy differently than do batteries. More specifically, energy is stored electrostatically in UCAPs on the surface of the electrode and does not involve chemical reactions as occur in batteries.

Methodology Applied
Scientific EffectElectrostatic energy storage: Capacitance

Implementation Method 2

conductive hardware to physically connect the cells in series... at least one UCAP terminal rod used to route power within the apparatus

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11495974B2Modular ultracapacitor energy storage/power delivery apparatus and methods
Publication Date: 2022.11.08 MAXWELL TECHNOLOGIES GLOBAL LLC
  • US11495974B2 patent drawing
  • US11495974B2 patent drawing
  • US11495974B2 patent drawing

AI summary

A modular integrated ultracapacitor-based energy storage and power delivery apparatus (UCAP module) is described. In some embodiments, the UCAP module comprises: at least one ultracapacitor cell coupled together in a series, parallel, or combination of both series and parallel configuration; an integrated charging unit; conductive hardware electrically coupling the ultracapacitors cells together; at least one UCAP terminal rod extending throughout the UCAP module and used to route power within the UCAP module and in some embodiments to other UCAP modules; and a protective casing. In some embodiments the UCAP terminal rod couples the UCAP module to at least one additional UCAP module in a series, parallel, or a combination of both series and parallel configurations. In other embodiments, the UCAP module further comprises connector rods that electrically and mechanically couple the UCAP module to at least one additional UCAP module.