Supercapacitor Cooling via Internal Thermal Conduit
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Solution Overview
Problem
Supercapacitors face overheating issues due to their construction and packaging, which limits their lifespan and makes cooling challenging, especially in high-temperature environments like vehicle engine compartments, and existing cooling solutions are either ineffective or impractical for complex modules.
Innovation Solution
A packaging design for electrical storage elements that includes a conduit for thermal conditioning fluid, where the pipe is longer than the storage element and projects from both ends, allowing for internal and external cooling without the need for additional insulation, enabling the formation of complex modules while preventing liquid penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If supercapacitors are packaged in insulating plastic or metal enclosures to protect from water and humidity, then protection against liquid penetration is improved, but heat dissipation deteriorates causing significant heating within the supercapacitors
Solution Approach 1:
The patent uses a plastic envelope that is tight against liquids and gases generated inside the supercapacitor but allows thermal conditioning. The envelope is designed to be permeable to heat while impermeable to liquids, resolving the contradiction between protection and heat dissipation.
Solution Approach 2:
The patent introduces a thermal conditioning fluid as an intermediary substance that circulates through the envelope to transfer heat away from the supercapacitor. This mediator allows the insulating envelope to protect against liquids while the fluid carries away the heat that would otherwise accumulate.
2Temperature
If additional cooling means are added to supercapacitors, then temperature control is improved, but the risk of leaks to fluids and electricity increases
Solution Approach 1:
The patent makes the envelope itself serve the dual function of liquid protection and thermal conditioning by incorporating the cooling fluid circulation directly into the envelope structure. This eliminates the need for separate cooling components that would create additional leak paths.
Solution Approach 2:
The patent merges the protective envelope function with the thermal management function into a single integrated structure. The plastic envelope simultaneously provides liquid tightness and serves as the cooling system, reducing the number of separate components and potential leak points.
3Power
If supercapacitors are arranged in the engine compartment for high power applications, then power delivery capability is improved, but the hot environment complicates cooling and reduces lifespan
Solution Approach 1:
The patent ensures continuous thermal conditioning by having the cooling fluid circulate continuously through the envelope. This continuous action maintains effective heat removal even in the high-temperature engine compartment environment, allowing the supercapacitor to sustain high power delivery without thermal degradation.
4Ease of manufacture
If the maximum unit voltage of supercapacitors is limited to approximately 2.7 Volts due to construction technology, then manufacturing simplicity is maintained, but additional series/parallel associations are required increasing device complexity
Solution Approach 1:
The patent makes the envelope serve multiple functions: liquid protection, thermal conditioning, and structural support for the voltage association architecture. This multi-functionality helps manage the complexity introduced by series/parallel associations by integrating several roles into a single component.
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
This design effectively manages temperature within supercapacitors, enhancing their lifespan by allowing better cooling and preventing liquid exposure, making it suitable for high-power applications like hybrid vehicles without the need for additional enclosures.
Implementation Method 1
a first electrical storage element traversed by a conduit for the passage of a thermal conditioning fluid
Implementation Method 2
the pipe is of a length greater than that of the electric storage element and projects from the latter at each of these ends
Data Source
Figure 1
Figure 2~2A
Figure 3~3A
AI summary
The device has an energy storage element (10) e.g. ultracapacitor, crossed by a conduit (22) used for passage of thermal packaging fluid, and male and female collectors (12, 13) forming positive and negative poles of the device. The conduit has length higher than that of the energy storage element. The conduit extends beyond the storage element and is opened at level of a convex surface (15) of the collectors. The positive and negative poles are located on opposite faces of the storage element through which the conduit is opened.