Segmented Ultracapacitor Enclosure for Stable Vibration Resistance

Solution Overview

Problem

Ultracapacitor modules face mechanical and performance failures due to shock and vibration, with existing damping solutions providing inadequate stability over time and being difficult to integrate into the module.

Innovation Solution

The ultracapacitor module features a secure enclosure with interlocking mechanisms and adhesive sealing, ensuring that at least one ultracapacitor is firmly attached to the enclosure, maintaining structural integrity and performance even under challenging vibration profiles as per ISO 16750-3-2012 and IEC 60068-2-64 standards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If damping elements are provided to reduce vibration effects, then vibration resistance is improved, but the stability over time deteriorates and insertion difficulty increases

Engineering Contradiction:

Improvevibration resistanceVSAvoidstability over time

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The enclosure is divided into multiple segments (first enclosure member, second enclosure member, third enclosure member) that are interconnected through openings and fastening mechanisms. Each segment independently secures components while distributing vibration stresses, preventing single-point failure and maintaining long-term stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple protective functions into a unified enclosure structure that integrates vibration resistance, component security, and long-term stability. The interconnected enclosure members work together as a single system to dampen vibrations while maintaining structural integrity over time.

Inventive Principle:

Principle #5Merging (Combining)

2Object-affected harmful factors

If damping elements are provided to reduce vibration effects, then vibration resistance is improved, but insertion difficulty increases

Engineering Contradiction:

Improvevibration resistanceVSAvoidinsertion difficulty

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The enclosure is divided into multiple segments (first enclosure member, second enclosure member, third enclosure member) that are interconnected through openings and fastening mechanisms. Each segment independently secures components while distributing vibration stresses, preventing single-point failure and maintaining long-term stability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent combines multiple protective functions into a unified enclosure structure that integrates vibration resistance, component security, and long-term stability. The interconnected enclosure members work together as a single system to dampen vibrations while maintaining structural integrity over time.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If ultracapacitors are secured to the enclosure, then vibration resistance is improved, but device complexity increases

Engineering Contradiction:

Improvevibration resistanceVSAvoidstructural complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The enclosure members serve multiple functions: they provide structural containment, secure ultracapacitors through integrated fastening mechanisms, dampen vibrations, and maintain electrical connections. This multi-functionality reduces the need for separate components, thereby managing complexity while improving vibration resistance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent creates a unified structural environment where all enclosure members and ultracapacitors are integrated into a single vibration-resistant system. The interconnected structure ensures uniform stress distribution and consistent protective performance across all components.

Inventive Principle:

Principle #12Equipotentiality

Data Source

PatentUS11742156B2Ultracapacitor module with improved vibration resistance

Publication Date: 2023.08.29 KYOCERA AVX COMPONENTS CORP

AI summary

An ultracapacitor module is disclosed. The ultracapacitor module comprises: an enclosure, and a plurality of ultracapacitors housed within the enclosure wherein at least one ultracapacitor of the plurality of ultracapacitors is secured to the enclosure. The ultracapacitor module satisfies one or more of the following conditions upon being subjected to a vibration profile in accordance with ISO 16750-3-2012, Table 12 and IEC 60068-2-64: a capacitance within a rated capacitance value as determined in accordance IEC 62391-1, Method 1A, an equivalent series resistance within a rated equivalent series resistance value as determined in accordance IEC 62391-1, a leakage current within a rated leakage current value as determined in accordance IEC 62391-1, an operating voltage with a rated operating voltage value.