Series-Connected Supercapacitor Encapsulation for High Voltage Low ESR
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Solution Overview
Problem
Supercapacitor modules face challenges with low operating voltages and high equivalent series resistance (ESR), especially in humid environments, which can lead to corrosion and reduced performance.
Innovation Solution
A supercapacitor module design that connects two supercapacitors in series with an interconnect, encapsulated in a casing, achieving an operating voltage greater than 3.5 volts and ESR less than 10 ohms, using carbonaceous coatings and ionic liquids, and optionally incorporating a balancing circuit and specific materials for the casing to enhance durability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If supercapacitors are connected in series to increase operating voltage, then voltage increases, but equivalent series resistance increases
Solution Approach 1:
A conformal coating is applied as an intermediary protective layer between the supercapacitor components and the external environment. This coating prevents harmful interactions while maintaining electrical performance, allowing series connection without the expected penalty in ESR.
Solution Approach 2:
The patent changes the physical and chemical parameters of the encapsulation environment by introducing a conformal coating with specific dielectric properties. This modifies the electrical characteristics of the module, enabling high voltage operation with controlled ESR through parameter optimization of the coating material and thickness.
2Quantity of substance
If supercapacitors are surface mounted in confined spaces, then energy storage density increases, but heat and humidity accumulation causes corrosion and damage
Solution Approach 1:
The conformal coating creates an inert protective environment around each supercapacitor, isolating them from harmful external factors such as humidity and heat. This allows dense surface mounting in confined spaces while preventing the corrosion and damage that would otherwise occur in high-humidity environments.
Solution Approach 2:
A thin conformal coating film is applied to each supercapacitor, providing flexible protection against environmental factors. This thin film approach maintains the compact form factor needed for high energy density while effectively blocking harmful moisture and heat from reaching the supercapacitor components.
3Ease of operation
If electrical leads are used to connect supercapacitors to PCBs, then electrical connection is achieved, but heat generation and electrolysis reactions damage the supercapacitors
Solution Approach 1:
The conformal coating serves as an intermediary protective barrier between the electrical leads/PCB interface and the supercapacitor body. This coating prevents direct exposure to harmful effects from connection currents, blocking heat transfer and preventing electrolysis reactions while maintaining the necessary electrical connection functionality.
Data Source
AI summary
A supercapacitor module is provided. In some embodiments, the supercapacitor can include a first supercapacitor, a second supercapacitor, and an interconnect electrically connecting the first and second supercapacitors in series. A casing can encapsulate at least the first and second supercapacitors. The operating voltage of the supercapacitor module can be greater than 3.5 volts, and the equivalent series resistance of the supercapacitor module can be less than about 10 ohm.