Ultra Capacitor Module Series Connection Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing ultra capacitor modules face increased production costs and assembly complexity with rising component numbers, heat generation due to contact resistance, and susceptibility to cell voltage imbalance, leading to reduced lifespan and potential explosions when connecting multiple ultra capacitors in series.
Innovation Solution
An ultra capacitor module design featuring a connecting member with screw threads on both ultra capacitors and a printed circuit board with a cell balancing function, utilizing a single nut for series connections and an elastic member for easy PCB rotation, which reduces component count, minimizes heat resistance, and includes a gas emission hole to prevent explosions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple busbars and nuts are used to connect ultra capacitors in series, then the connection structure is established, but production costs increase and assembly complexity increases
Solution Approach 1:
The patent combines multiple separate connecting components (busbars and nuts) into a single integrated connecting member. This connecting member has a body portion that contacts one ultra capacitor terminal and a fastening portion with a nut that secures the other terminal, eliminating the need for separate busbars and multiple nuts while maintaining reliable electrical connection.
Solution Approach 2:
The connecting member serves multiple functions simultaneously: it provides electrical connection through its conductive body, mechanical fastening through the integrated nut, and structural support for the ultra capacitor assembly. This multi-functional design reduces the total component count and simplifies the overall structure.
2Reliability
If multiple busbars and nuts are used to connect ultra capacitors, then the connection structure is established, but the number of components increases leading to higher production costs
Solution Approach 1:
The patent merges the functions of separate busbars and nuts into a single integrated connecting member, reducing the component quantity from multiple parts to one unified component while maintaining stable electrical and mechanical connections.
Solution Approach 2:
The connecting member is segmented into functional portions (body portion for electrical contact and fastening portion for mechanical securement), allowing each section to perform its specific function optimally while being part of a single reduced-component assembly.
3Reliability
If busbars are used to connect ultra capacitors, then electrical connection is established, but contact resistance increases causing heat generation
Solution Approach 1:
The connecting member appears to utilize composite construction with conductive materials optimized for low electrical resistance. The integration of the fastening portion directly with the conductive body ensures optimal electrical contact and minimizes contact resistance at the connection interface, reducing heat generation during operation.
4Ease of operation
If a bolting part is formed on the nut for harness connection, then the balancing board connection is enabled, but production costs increase due to additional processing
Solution Approach 1:
The patent integrates the harness connection function directly into the fastening portion of the connecting member. The bolting part is formed as an integral feature of the nut structure, combining the fastening and electrical connection functions in one component without requiring separate processing steps or additional parts.
Solution Approach 2:
The fastening portion serves dual purposes: mechanically securing the ultra capacitor terminal with the nut and providing a connection point for the balancing board harness. This multi-functional design eliminates the need for separate bolting parts and reduces manufacturing complexity.
Data Source
Figure 1
Figure 2~3(b)
Figure 4
AI summary
Disclosed is an ultra capacitor module. The ultra capacitor module according to the present disclosure includes a first ultra capacitor having a first polar terminal provided with a screw thread A formed on an outer peripheral surface, a second ultra capacitor having a second polar terminal provided with a screw thread A formed on an outer peripheral surface, and a connecting member having a screw hole B formed corresponding to the screw thread A on an inner peripheral surface through which the first polar terminal is inserted from one side and the second polar terminal is inserted from the other side to connect the first and second ultra capacitors in series and having a gas emission hole formed from a center to an outer surface.