Modular Ultracapacitor Packaging with Pluggable Busbars
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Solution Overview
Problem
Existing energy storage systems, such as batteries, face challenges with short life expectancy and low power density, which are addressed by ultracapacitors but require effective packaging and connection solutions for efficient use in automotive and stationary applications.
Innovation Solution
A modular ultracapacitor energy storage system with a coupling system for pluggable connection and thermal management, incorporating busbars for series and parallel connections, and a controller for voltage monitoring and fault detection, designed for secure, water-sealed, and vibration-resistant environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ultracapacitors are used to improve power density and life expectancy, then energy storage performance is improved, but packaging and connection complexity increases
Solution Approach 1:
The system divides ultracapacitor modules into separate, standardized units that can be independently packaged and connected. Each module contains its own housing with integrated connection terminals, allowing the system to be assembled from modular components rather than requiring complex integrated packaging of all ultracapacitors together.
Solution Approach 2:
The housing structure serves multiple functions simultaneously: it provides mechanical protection for the ultracapacitors, acts as a structural support element, provides thermal management pathways, and integrates connection terminals for electrical connections. This multi-functionality reduces the need for separate components and simplifies overall system packaging.
2Quantity of substance
If ultracapacitors are connected in series and parallel configurations, then energy storage capacity is improved, but connection complexity and manufacturing difficulty increase
Solution Approach 1:
The system uses standardized modular units with predefined connection interfaces that can be easily assembled in series or parallel configurations. Each module has standardized terminals that simplify the connection process, allowing flexible capacity scaling without requiring complex custom wiring arrangements.
Solution Approach 2:
The system achieves different energy storage capacities by changing the number of modules connected in series or parallel, rather than requiring different internal configurations within each module. This allows flexible capacity adjustment through simple addition or removal of standardized modules, simplifying manufacturing and assembly.
3Ease of operation
If modular pluggable connection system is implemented, then ease of installation and maintenance is improved, but connection reliability and security may be compromised
Solution Approach 1:
The connection terminals are pre-positioned and pre-configured within the housing during manufacturing, with alignment features that guide proper insertion. This preliminary preparation ensures that field installation and maintenance operations are simple and error-free, while maintaining secure electrical connections through precision-engineered contact surfaces.
Solution Approach 2:
The design includes built-in tolerance compensation features and contact surface geometries that accommodate minor misalignments or wear over time. This beforehand cushioning ensures that pluggable connections maintain reliable electrical contact even after repeated insertions and environmental exposure, without requiring complex adjustment mechanisms.
Data Source
AI summary
An ultracapacitor energy storage system and in particular a system for packaging and connecting ultracapacitors (15) for energy storage purposes is described which is applicable in automotive and stationary applications. The ultracapacitors (15) in the system can be in series or parallel or a combination of both. A controller, relays, voltage monitoring and isolation fault detection are used to regulate the system. The mechanical construction of frame and different pluggable modules (2 and 7) lead to an easy in- and de-installation of the different parts. The different constructions are designed with a safe handling by the operator in mind.