US20130266825A1 - Ultracapacitor and battery device with standard form factor - Google Patents

Ultracapacitor and battery device with standard form factor Download PDF

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Publication number
US20130266825A1
US20130266825A1 US13/797,358 US201313797358A US2013266825A1 US 20130266825 A1 US20130266825 A1 US 20130266825A1 US 201313797358 A US201313797358 A US 201313797358A US 2013266825 A1 US2013266825 A1 US 2013266825A1
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Prior art keywords
battery
capacitor
enclosure
ultracapacitor
form factor
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Abandoned
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US13/797,358
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English (en)
Inventor
Jeremy Cowperthwaite
Takao Shimbori
Mikael Setterberg
Priya Bendale
Thomas J. Dougherty
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Tesla Inc
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Maxwell Technologies Inc
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Assigned to MAXWELL TECHNOLOGIES, INC. reassignment MAXWELL TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DOUGHERTY, THOMAS J., COWPERTHWAITE, Jeremy, BENDALE, PRIYA, SETTERBERG, MIKAEL, SHIMBORI, Takao
Publication of US20130266825A1 publication Critical patent/US20130266825A1/en
Assigned to EAST WEST BANK reassignment EAST WEST BANK SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MAXWELL TECHNOLOGIES, INC.
Assigned to MAXWELL TECHNOLOGIES, INC. reassignment MAXWELL TECHNOLOGIES, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: EAST WEST BANK
Assigned to MAXWELL TECHNOLOGIES, INC. reassignment MAXWELL TECHNOLOGIES, INC. RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: EAST WEST BANK
Assigned to TESLA, INC. reassignment TESLA, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MAXWELL TECHNOLOGIES, INC.
Abandoned legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
    • H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
    • H01G9/28—Structural combinations of electrolytic capacitors, rectifiers, detectors, switching devices with other electric components not covered by this subclass
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES, LIGHT-SENSITIVE OR TEMPERATURE-SENSITIVE DEVICES OF THE ELECTROLYTIC TYPE
    • H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
    • H01G11/08—Structural combinations, e.g. assembly or connection, of hybrid or EDL capacitors with other electric components, at least one hybrid or EDL capacitor being the main component
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M16/00—Structural combinations of different types of electrochemical generators
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/10—Primary casings; Jackets or wrappings
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/204—Racks, modules or packs for multiple batteries or multiple cells
    • H01M50/207—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape
    • H01M50/209—Racks, modules or packs for multiple batteries or multiple cells characterised by their shape adapted for prismatic or rectangular cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/253—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders adapted for specific cells, e.g. electrochemical cells operating at high temperature
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M50/00—Constructional details or processes of manufacture of the non-active parts of electrochemical cells other than fuel cells, e.g. hybrid cells
    • H01M50/20—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders
    • H01M50/296—Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders characterised by terminals of battery packs
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2207/00—Indexing scheme relating to details of circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J2207/20—Charging or discharging characterised by the power electronics converter
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10—Energy storage using batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/13—Energy storage using capacitors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/43—Electric condenser making
    • Y10T29/435—Solid dielectric type
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making

Definitions

  • the present disclosure relates generally to a combined capacitor and battery combination, and related methods of making and using such combinations.
  • a battery may have limited cycle efficiency, and thus may experience decreased recharge performance, or even completely lose its ability to charge after a given number of charge/discharge cycles.
  • the cycle efficiency of a battery may decrease when used in a vehicle that starts and stops the engine repeatedly, such as in a hybrid vehicle that engages a starter regularly to adjust from electric to gas power.
  • the cycle efficiency of a battery may also be affected under some temperature conditions, as described further below. It will be understood that while reference is made herein to hybrid vehicles and vehicles with an internal combustion engine, embodiments described herein may be employed within other vehicle or non-vehicle systems.
  • CCA Cold Cranking Amps
  • CA Cranking Amps
  • RC Reserve Capacity
  • the battery system includes an enclosure, a battery disposed within the enclosure, and at least one ultracapacitor.
  • the ultracapacitor is disposed within the enclosure and coupled to the battery to provide electrical energy via battery terminals.
  • the enclosure conforms to a standard form factor for a battery that comprises one or more conventional storage cells without an ultracapacitor.
  • the battery system includes an enclosure having dimensions, mounting features and terminal locations conforming to a standard group specified by the Battery Council International.
  • a battery is disposed within the enclosure.
  • At least one ultracapacitor is disposed within the enclosure and coupled to the battery to provide electrical energy via battery terminals.
  • Control or regulation circuitry is disposed in the enclosure and coupled to the battery and ultracapacitor.
  • the battery system includes an enclosure, a battery disposed within the enclosure, and at least one ultracapacitor.
  • the ultracapacitor is disposed within the enclosure and coupled to the battery to provide electrical energy via battery terminals.
  • Output of the battery and ultracapacitor and a form factor of the enclosure conform to a standard voltage rating and a standard form factor to permit retrofitting of a battery that comprises one or more conventional storage cells without an ultracapacitor.
  • FIG. 1 illustrates an embodiment of a capacitor/battery combination energy storage device.
  • FIG. 2A is a front perspective cross-sectional cutaway and exploded view of an embodiment of a two-terminal capacitor/battery combination energy storage device.
  • FIG. 2B is a left perspective view of a capacitor bank that can be implemented within a capacitor/battery combination energy storage device.
  • FIG. 3 is a front perspective cross-sectional cutaway view of an embodiment of a three-terminal capacitor/battery combination energy storage device.
  • FIG. 4 is a front perspective exploded view of an embodiment of a capacitor/battery combination energy storage device.
  • FIG. 7 is a side view of an embodiment of a capacitor/battery combination energy storage device with a flexible bus bar.
  • FIG. 10 is a schematic diagram illustrating an embodiment of the capacitor/battery combination energy storage device shown in FIG. 9 , with a current limiter in series with the rectifier.
  • FIG. 13 is a schematic diagram illustrating another embodiment of the capacitor/battery combination energy storage device of FIG. 12 , with the DC/DC converter in parallel with the main rectifier.
  • FIG. 14A is a schematic diagram illustrating an embodiment of a two-terminal capacitor/battery combination energy storage device with two switches.
  • FIG. 15 is a schematic diagram illustrating an embodiment of a three-terminal capacitor/battery combination energy storage device with one switch.
  • FIG. 16 is a schematic diagram illustrating an embodiment of a three-terminal capacitor/battery combination energy storage device with a current limiter between two of the terminals.
  • FIG. 17 is a schematic diagram illustrating an embodiment of a three-terminal capacitor/battery combination energy storage device with a network of rectifiers.
  • FIG. 18 is a schematic diagram illustrating another embodiment of a two-terminal capacitor/battery combination energy storage device with a capacitor bank and a battery bank.
  • Some embodiments of the invention relate to systems and methods of providing a combination energy storage device that includes a battery system in combination with a capacitor system.
  • the battery system may have one or more batteries and the capacitor system may have one or more capacitors.
  • the capacitors may be based on various technologies, such as an ultracapacitor, also known as a supercapacitor or electric double-layer capacitor. Examples of ultracapacitors can be found, for example, in U.S. Pat. Nos. 7,791,860; 7,352,558; 7,342,770; 8,072,734; and 7,508,651. Examples of combined battery and ultracapacitor devices can be found, for example, in U.S. Patent Application Publication No.
  • the combined energy storage device includes a battery and a capacitor in a single, integrated package.
  • a symmetric capacitor in which a similar material is used for both electrodes, may be employed.
  • an asymmetric capacitor in which different materials are used for the two electrodes, may be employed.
  • the combined energy storage device includes a single, integrated package that is of similar size to the standard vehicle non-hybrid batteries available on the open market (“OEM” batteries).
  • a “capacitor” and “battery” as described herein can refer to a single capacitor or battery, respectively, or a plurality of capacitors or batteries, respectively, as in a capacitor bank or battery bank connected in series or in parallel.
  • Implementing a capacitor in combination with a battery in a combined battery/capacitor energy storage device can help reduce or mitigate one or more of the aforementioned limitations of an energy storage system that includes only a battery for energy storage.
  • a capacitor generally can sustain an increased number of discharge/charge cycles, and thus has a longer cycle life, than a comparable battery.
  • a combined energy storage device that uses a capacitor in combination with a battery may thus provide improved cycle life, and may provide benefits to an application with increased charge/discharge cycles, such as a start/stop application.
  • a capacitor generally may also provide a more efficient delivery of power, and a quicker charge and discharge time than a comparable battery. Such improved capacitor efficiency may result from the generally more efficient charge acceptance, higher discharge rate and faster chemical kinetics, of a capacitor relative to a comparable battery.
  • a capacitor may also have a lower equivalent series resistance (ESR) than the resistance of a comparable battery.
  • ESR equivalent series resistance
  • a capacitor generally does not experience the aforementioned drop in voltage as a battery may, when a power supply, such as an alternator stops charging.
  • a capacitor also has a reduced tendency to “cycle down” over time with respect to that of a battery.
  • a capacitor used in combination with a battery was found to reduce the peak current stress experienced by the battery during use.
  • a capacitor may also generally be less susceptible to some temperature effects than a battery.
  • a capacitor can sustain a charge and/or retain higher voltages at lower temperatures, and thus can deliver higher power, than a comparable battery at the same temperature, or a comparable capacitor at a higher temperature.
  • Such aspects of a capacitor were found to provide improved performance, for example, of a vehicle ignition system when the capacitor was used to provide power to a starter.
  • a capacitor when disconnected from an alternator or other power source, it has higher output voltage, or open circuit voltage, and exhibits lower voltage drop under load than a comparable battery under similar conditions.
  • Such decreased voltage drop of a capacitor can also translate into increased cranking power, and thus a faster crank speed of a vehicle starter, when the capacitor is employed within a vehicle energy storage system.
  • the aforementioned improvements in the voltage drop of a capacitor may be enhanced at lower temperature conditions.
  • a capacitor used in combination with a battery in an energy storage device was found to provide a reserve or backup energy source in the event of reduced battery performance or failure (for example, to provide emergency lighting power, starter, or alternator power).
  • One embodiment is a battery and ultracapacitor combination in a combined energy storage device.
  • the battery and ultracapacitor can be packaged together in a combination device in a number of different ways.
  • some embodiments include a combined battery/capacitor storage device that forms a battery system for a “drop-in” replacement for one or more batteries in a vehicular battery system, such as a Battery Council International (BCI) Group 31 battery.
  • BCI Battery Council International
  • one of ordinary skill in the art could use teachings of the present disclosure to create combined capacitor/battery systems that are designed to meet other OEM sizes and standards, such as those in the BCI Groups, as described further below.
  • some embodiments include a combined battery/capacitor storage device that has a housing of substantially the same dimensions, mounting features and/or terminals of similar positioning and/or size, and/or similar output ratings, as an OEM battery.
  • the battery and ultracapacitor are selected to provide output of 6 or 12 volts, and the standard form factor conforms to a corresponding 6 or 12 volt battery.
  • the standard form factor conforms to a standard for a lead-acid battery.
  • output of the battery and ultracapacitor and a form factor of the enclosure conform to a standard voltage rating and a standard form factor to permit retrofitting of a battery that comprises one or more conventional storage cells without an ultracapacitor.
  • Some embodiments include methods for making such a battery system, comprising, in an enclosure that conforms to a standard form factor, disposing a battery and at least one ultracapacitor coupled to the battery to provide electrical energy via battery terminals external to the combined hybrid energy storage device. Some embodiments include providing an assembly of the energy storage device described herein, with at least one adapter that adapts the enclosure for mounting in place of a standard form factor for a battery that comprises one or more conventional storage cells without an ultracapacitor.
  • the enclosure can be smaller than the standard form factor for the battery in the place of which it is to be mounted, or can be differently shaped than the standard form factor for the battery in the place of which it is to be mounted.
  • FIG. 1 illustrates an embodiment of a hybrid capacitor/battery combination energy storage device 10 .
  • Hybrid device 10 can include an enclosure or housing 12 forming an interior cavity into which one or more capacitors 20 (e.g., EDLCs) and a battery 30 can be placed.
  • Housing 12 can comprise sidewalls 11 , a lid 13 , and a base 15 to form its interior cavity. Lid 13 can be permanently or removably attached to the remainder of housing 12 .
  • External device terminals 48 and 49 can be attached to lid 13 and be configured to connect device 10 to an external system.
  • the device terminals 48 and 49 can be sized and shaped to correspond to an external battery terminal for a standard form factor battery.
  • the device 10 can include a third device terminal, to provide additional functionality, as described in some of the embodiments herein.
  • the terminals can extend from at least one of a top, front and side location on the housing 12 .
  • the device 10 can be sized with a height H, width W and depth D to conform to a standard OEM battery, such as any one or more of the BCI Group sizes listed in the following Table 1:
  • the approximate maximum heights listed in Table 1 include the terminal posts. Width and length measurements are generally to the widest point, including protruding flanges, except for hold-down flanges at the bottom of the battery. It will be understood that other OEM sizes can be implemented, including BCI Group sizes not listed, such as Heavy-Duty Motor Coach, Bus, and Special Tractor Batteries.
  • the EDLC 20 can include electrodes and electrolyte contained within a housing 22 of each EDLC, as is known in the art.
  • a plurality of the EDLCs 20 can be electrically connected in series or in parallel to form a capacitor bank.
  • the battery 30 can include a housing 32 with an interior battery cavity configured to contain battery plates, electrolyte and other components, as is known in the art.
  • Housing 32 of the battery 30 can include a lid 33 , base 35 , and sidewalls 31 to form its interior cavity.
  • the battery 30 can be a standard OEM battery, such as a BCI Group size.
  • the embodiment in FIG. 1 may include additional packaging material and structure, as it includes the housings 22 , 32 for the EDLCs 20 and battery 30 , respectively, and the housing 12 for the overall hybrid device 10 .
  • the interior cavity 116 can be separated into a plurality of sub-cavities 116 A, through a series of partitions 119 within the battery housing portion 114 .
  • Each sub-cavity 116 A can house a battery electrode, to form one or more individual battery cells within cavity 116 .
  • Each battery cell can include a positive and negative battery cell terminal (not shown). These battery cell terminals can be electrically connected together in a manner similar to a known, discrete OEM battery, and placed in electrical communication with internal battery terminals 41 and 42 extending through the lid 133 .
  • the “internal battery terminals” can be defined as the external terminals for a discrete battery placed within the energy storage device housing, or the battery terminals of an integrated battery formed within the integrated battery housing, as described further herein.
  • Embodiments of device 100 with the integrated battery housing 114 shown in FIG. 2A may eliminate the need for one or more sidewalls 31 and base 35 of the battery housing 32 shown in FIG. 1 .
  • device 100 can allow battery 130 to be integrated directly within the device housing 112 of hybrid energy storage device 100 , without requiring an entire, additional, separate external battery housing.
  • all or a portion of the integrated device housing 112 of device 100 can comprise an integrally-formed, unitary component.
  • the sidewalls 111 A- 111 D, base 115 and inner sidewall 117 can be an integrally formed unitary component, for example, through a molding or other suitable process.
  • the capacitor housing portion 124 of the device 100 can be sized and shaped to house capacitors of various quantities, sizes, shapes and/or orientations, and may be sized and shaped to house capacitors of more than one size, or shape, or orientation.
  • the capacitor housing portion 124 may be expandable, and/or may be sized to include extra room to allow for expansion of capacitor capacity.
  • the housing portion 124 shown in FIG. 2A can be configured to extend horizontally or vertically with respect to the view shown, or tangentially (into/out of the plane of the view shown).
  • the capacitors 120 A- 120 F are shown in an approximately horizontal orientation in FIG. 2A
  • the EDLCs can be oriented vertically, horizontally, tangentially, in one or more rows or columns, or combinations thereof.
  • FIG. 3 is a front perspective cross-sectional cutaway view of a three-terminal embodiment of an integrated capacitor/battery device 200 .
  • Device 200 can be similar to device 100 shown in FIG. 3 , but with a third device terminal 50 to provide additional functionality. Further details regarding the functionality of device 200 , and the wiring, terminal and bus bar configurations shown in FIGS. 2 and 3A are provided below.
  • FIGS. 4 and 5 are front perspective exploded views of embodiments of a combination capacitor/battery device 100 A, 100 B, respectively.
  • the embodiments shown in FIGS. 4 and 5 can be similar to those in FIGS. 2A-3 , with one or more of the following differences.
  • sidewalls 111 B can extend downwardly from the lid 213 to form the capacitor housing portion 224 and enclose the capacitor 120 .
  • the sidewalls 111 B can be configured as a separate section that can form the capacitor housing portion 224 , with lid 213 being a separate component.
  • the device housing and its various portions described herein can be separately or integrally formed in a variety of methods.
  • the embodiment shown in FIGS. 4 and 5 may have improved weight distribution for handling etc., as the battery, which can generally be denser, and thus, heavier than the EDLC, is distributed approximately evenly across the width of the overall device 10 .
  • the battery is positioned below the capacitor, to prevent toppling of the device, which further improves weight distribution and handling.
  • a Group 75/25 Battery with dimensions of 9.3 inch (L) ⁇ 6.8 inch (W) ⁇ 7.0 inch (H) can be employed.
  • the integrated battery can be configured to occupy approximately the lower 2 ⁇ 3 of the container.
  • the capacitors can occupy an estimated remaining 9.0 inch (L) ⁇ 6.5 inch (W) ⁇ 2.3 (H) inch of volume within the capacitor housing portion. It will be understood that this embodiment is not to be limited to a Group 75/25 Battery, or the voltages and dimensions described, and is merely for illustrative purposes.
  • FIGS. 6A and 6B are a side cross-sectional and an exploded side cross-sectional view, respectively, illustrating embodiments of electrical connections, terminal and bus-bar configurations that can be implemented within a combined batter/capacitor storage device, such as those shown in FIGS. 2A and 3 .
  • FIG. 2B is a left perspective view of a capacitor bank that can be implemented within a capacitor/battery combination energy storage device, such as devices 100 and 200 from FIGS. 2A and 3 .
  • FIGS. 2A , 3 , 6 A and 6 B are shown in the context of a side-by-side or horizontally adjacent combined battery/capacitor device.
  • similar features can be employed for the terminal and bus-bar configuration of an over-under or vertically adjacent combined battery/capacitor device, such as those described herein and shown in FIGS. 4 and 5 .
  • the embodiments shown can be employed for the bus-bar configuration of an energy storage device with an integrated battery or a discrete battery.
  • capacitors 120 A- 120 F can each include capacitor terminals 123 A and 123 B, which can be connected in series or parallel with respect to each other to form capacitor bank 120 .
  • the terminals 123 A and 123 B can be connected with a plurality of capacitor interconnects, bus bars, etc.
  • capacitor interconnects 121 A- 121 E extend between and electrically connect the terminals 123 A, 123 B of adjacent capacitors in bank 120 .
  • the interconnect 121 A ( FIG. 2A ) can connect a terminal 123 A of capacitor 120 A with a terminal 123 B of capacitor 120 C, and so forth.
  • capacitors 120 A- 120 F are connected in series with interconnects 121 A- 121 E, such that terminal 123 B of capacitor 120 A forms a first capacitor bank terminal 125 and terminal 123 A of capacitor 120 B forms a second capacitor bank terminal 127 .
  • the combined battery/capacitor device 100 can be configured as a two-terminal device, comprising two internal battery terminals 41 and 42 .
  • the battery terminals 41 , 42 can include one or more openings 43 extending through each terminal.
  • the openings 43 can comprise a bushing or a threaded opening.
  • the battery terminals 41 , 42 can be insert-molded into the battery lid 33 .
  • the internal battery components can include an internal terminal post configured to engage with the opening 43 .
  • the internal terminal post can comprise any suitable terminal material, such as lead.
  • the internal terminal post can engage with the opening 43 in various ways, such as by induction welding.
  • the internal threads on the battery terminals 41 , 42 can be used to connect the battery to the capacitor bank 120 , as well as an external terminal to the combined energy storage device, as described further below.
  • the first battery terminal 41 can be connected with a first bus bar 44 to the first capacitor bank terminal 125 of the capacitor bank 120 .
  • the first bus bar 44 can be any of a number of shapes; in the illustrated embodiment, it comprises a downwardly extending portion 44 A that extends along a side of battery 130 and connects the battery terminal 41 with the capacitor terminal 125 ( FIG. 2B ).
  • An upwardly extending portion 44 B can extend along the side of battery 130 , with a laterally extending portion 44 C extending from portion 44 B to the first external device terminal 48 .
  • the first external device terminal 48 can extend from the first bus bar 44 , to connect the device 100 to an external system at a first point, such as a connection to a vehicle's electrical system (see, e.g., FIGS. 3A ; 6 A- 6 B; 8 - 18 ).
  • the second battery terminal 42 can be connected with a second bus bar 46 to the second capacitor terminal 127 of the capacitor bank 120 .
  • a second external device terminal 49 can extend from the second bus bar 46 , to connect the device 100 to an external system at a second point, such as a positive connection to a vehicle's electrical system (see, e.g., FIGS. 2A ; 6 A- 6 B; 8 - 18 ).
  • External device terminals 48 and 49 can be attached to a portion of the lid 113 of the integrated storage device 100 .
  • External device terminals 48 and 49 can be configured to correspond to the existing dimensions of the terminals of a standard OEM battery. It will be understood that the external device terminals described herein can extend from the lid 113 , sidewalls 111 A-D, base 115 , or other portions of energy storage device 100 .
  • the three-terminal embodiment of device 200 is similar to the two-terminal embodiment of device 100 shown in FIG. 2A , but with an additional external terminal 50 extending through the lid 113 from the second bus bar 46 .
  • Additional electronic components can be connected to one or more of the device terminals 48 , 49 and 50 , battery terminals 41 and 42 , bus bars 44 and 46 , capacitor terminals 45 and 47 , or elsewhere within device 200 , for additional functionality.
  • FIG. 3 shows electronic components 54 that can be positioned between portions 46 A and 46 B of bus bar 46 .
  • Embodiments of hybrid battery/capacitor energy storage devices with additional electronic componentry and functionality are described below with reference to FIGS. 8-18 .
  • FIGS. 6A and 6B show an embodiment of device 100 with details of the connection between external device terminal 48 , battery lid 133 , device lid 113 , bus bar 44 , and battery terminal 41 . Similar methods can be employed to connect the other external device terminals, bus bars, battery terminals, and capacitor terminals to the battery and device lids described herein, such as the others described with references to devices 100 and 200 . As shown, the external terminal 48 can extend through the device housing lid 113 , through the terminal bus bar 44 , and to the external battery terminal 41 .
  • a protruding stud 48 A of terminal 48 can be extended through an opening 13 A in device lid 113 .
  • the same portion of the terminal stud 48 A can be further extended into an opening 144 in the terminal bus bar 44 .
  • the same portion of the terminal stud 48 A can be further extended through the opening 144 in the terminal bus bar 44 , and into a mating portion 43 on the battery terminal.
  • the portion of the terminal stud 48 A can engage with one or more of the aforementioned openings, through a bushing or threaded connection.
  • the stud can engage with a corresponding portion on the capacitor terminal.
  • Such embodiments can allow one or more external terminals of a combined battery/capacitor energy storage device to function as a consolidated electrical and mechanical junction between the external terminal, bus bar and internal battery terminal, thereby reducing complexity of the energy storage device.
  • some embodiments can allow the battery terminals 41 , 42 of energy storage device 10 to be aligned with the external device terminals 48 , 49 or 50 , and the external device terminals 48 , 49 , or 50 can be installed from outside the energy storage device lid 113 , while also connecting to the bus bars 44 , 46 and the internal battery or internal capacitor terminals.
  • the external device terminals 48 , 49 or 50 can be installed through the device lid 113 , and connected to one of the bus bars 44 , 46 , without connecting directly to the capacitor battery terminals 41 , 42 or capacitor terminals 45 , 47 .
  • the terminal bus bars 44 and 46 can be routed in a number of different ways. In both the embodiments shown in FIGS. 2A and 3 , the terminal bus bars are routed in the space between the battery lid 133 and the device lid 113 (see also FIGS. 2A-2B ).
  • the external device terminals 48 , 49 or 50 can include a seal 51 configured to provide a seal against the housing lid. Additionally, to prevent galvanic corrosion at the joints between lead battery terminal or lead device external terminal and aluminum EDLC bus bars, a tin plating can be used on the aluminum bus bar, or grease that has been made for electrical joint application can be used.
  • the aforementioned structure and methods can provide for efficient assembly of the terminals and bus bars of embodiments of the combined battery/capacitor device described herein, with reduced number of linkages and parts.
  • FIG. 7 is a side view of an embodiment of combined battery/capacitor device 100 with a flexible bus bar 52 connected between battery terminal 41 and a capacitor terminal bus bar 144 .
  • the flexible bus bar 52 can provide sufficient flexibility to compensate for some relative movement between capacitor 20 and battery 30 . Such relative movement may be more prevalent when battery 30 and capacitor 20 are packaged together in a combined battery/capacitor device 10 .
  • the flexibility of flexible bus bar 52 can prevent wear and premature failure on bus bar 52 , thus increasing the reliability and life of energy storage device 10 .
  • the flexibility can be provided to bus bar 52 through its structural attributes and/or material.
  • the flexible bus bar 52 can comprise a material, such as copper bead, stranded wire, or braided wire, that is suitably flexible under a range of reasonable dimensions and environmental conditions for a bus bar as would be understood by a person having ordinary skill in the art.
  • a flat, braided electrical cable can be used. The ends of the electrical cable can be tinned and hole-punched to form an integrated lug.
  • bus bar 52 can include one or more curvilinear portions 53 that allow flexion of bus bar 52 , and relative movement between battery 30 and capacitor 20 .
  • FIGS. 8-18 are schematic diagrams showing various embodiments of electrical features that can be implemented within a capacitor/battery combination energy storage device, such as one or more of the devices 10 , 100 , 100 A, 100 B and 200 , described above with reference to FIGS. 1-7 .
  • the electrical features may comprise control or regulation circuitry disposed in the enclosure and coupled to the battery and ultracapacitor.
  • FIG. 8 is a schematic diagram illustrating an embodiment of a capacitor/battery combination device 300 with two external terminals 48 and 49 .
  • Terminal 48 can be a positive terminal and terminal 49 can be a negative or ground terminal.
  • One or more devices can be connected in parallel between terminals 48 and 49 .
  • capacitor 30 and battery 20 can be connected in parallel between terminals 48 and 49 .
  • the combined energy storage device 300 can be electrically connected to one or more vehicle loads.
  • the combined device 300 can be connected to a starter 60 or other vehicle loads (illustrated as car load 62 ).
  • the combined device 300 can also be connected to a power supply, such as an alternator 61 , in order to charge the combined device 300 as the vehicle is being driven.
  • a power supply such as an alternator 61
  • Other power supplies can be implemented instead of or in addition to alternator 61 , for any of the embodiments described herein and shown in the figures, unless otherwise specified.
  • another external power supply may be connected to device 300 to charge battery 20 , such as a charging station for an electric or hybrid vehicle.
  • the order and positioning of the car load 62 , alternator 61 , and starter 60 can be varied, and is provided in the order shown in FIG. 8 relative to the combined energy storage device 300 for illustrative purposes only.
  • Embodiments of the device 300 in FIG. 8 can allow both the capacitor 30 and the battery 20 to be charged from a power supply, such as the alternator 61 , and also supply power to a vehicle system, such as the starter 60 or other car loads 62 .
  • a power supply such as the alternator 61
  • vehicle system such as the starter 60 or other car loads 62 .
  • both the battery 20 and the capacitor 30 are charged from the alternator 61 with a charge voltage ranging from approximately 12-16V, with a typical average charge voltage being about 14.4V.
  • the battery Prior to being disconnected from the alternator 61 , the battery generally maintains a reasonably high state of charge.
  • the state of charge of the battery 30 may drop at the point the alternator 61 is turned off.
  • the capacity of battery 30 may drop to a point ranging from 65-85% of its rated capacity.
  • a battery capacity is measured in amp hours with a typical battery having a capacity of 60 amp-hours, although many batteries have more or less capacity depending on their cost and application.
  • one embodiment of the invention is a combined battery/capacitor system that allows a bi-directional flow between the capacitor 20 and battery 30 .
  • This provides a system wherein the capacitor 20 is configured to recharge the battery 30 when the state of charge and voltage in the capacitor 20 is higher than the battery 30 .
  • the increased cycle efficiency of the capacitor 20 can also allow the capacitor 20 to provide such function while increasing the life of the battery 30 , and thus the overall lifecycle of the device 10 . In effect, the capacitor 20 can absorb the “work” or power requirements that would otherwise be performed by the battery 30 .
  • the efficient charge acceptance and discharge rate of the capacitor 20 can allow it to mitigate some of the spikes and drops in power typical during operation of the device, such as in a start/stop application.
  • the two-terminal combined energy storage device 300 in FIG. 8 can also be more easily configured to replace a standard two-terminal OEM battery, for example, as a drop-in replacement.
  • the power management characteristics of embodiments of the two-terminal combined battery/capacitor energy storage device 300 can be affected when the battery 30 and capacitor 20 are configured in parallel, and when free-flow of current is allowed between the battery 30 , capacitor 20 , and starter 60 .
  • any current supplied to the vehicle starter 60 from the combined storage device 300 during a vehicle start event will be generated proportionally from both the battery 30 and the capacitor 20 , and will be affected by the resistance of the battery 30 , the ESR of the capacitor 20 , and the capacitance of the capacitor 20 .
  • the battery 30 supplied approximately 200 A of current and the ultracapacitor contributed approximately 600 A of current.
  • the available charge and voltage of the capacitor 20 will also generally move towards a charge and voltage equilibrium relative to that of the battery 30 when the alternator 61 or other power source is in an off state.
  • Such voltage equilibrium may generally be less than the state of charge and voltage of the capacitor 20 if it were to be electrically isolated from the battery 30 .
  • the battery voltage and state of charge may drop.
  • FIG. 9 shows an embodiment of a combined battery/capacitor energy storage device 400 , with many similar components as FIG. 8 .
  • the embodiment of energy storage device 400 in FIG. 9 can include a third terminal 50 , such as that shown in FIG. 3 .
  • the electronics schematically shown for the capacitor/battery combination device 400 can be implemented within the other three-terminal capacitor/battery combination devices described herein.
  • Terminal 48 can comprise a first positive terminal configured to connect with the alternator 61 .
  • Terminal 50 can comprise a second positive terminal that is configured to connect with starter 60 .
  • Such an embodiment can allow the starter 60 to be electrically configured on the same terminal of the device 300 as, for example, the capacitor 20 , and the alternator 61 to be electrically configured on the same terminal as the battery 30 .
  • embodiments are not limited to only connecting a starter 60 to the first positive terminal.
  • Terminals 48 and/or 50 can be configured to connect with other car loads 62 that would benefit from being directly connected to a capacitor or a battery.
  • a rectifierrectifier 63 can be positioned between the alternator terminal 48 and the starter terminal 50 .
  • the rectifier 63 can be configured to allow current flow from the alternator 61 to the capacitor 20 , allowing the capacitor 20 to be charged, while preventing or reducing current flow from the capacitor 20 to terminal 48 and battery 30 .
  • Such an embodiment can at least partially electrically isolate the capacitor 20 from the battery 30 .
  • some such embodiments also isolate the starter 60 from the battery 30 .
  • Rectifier 63 or any other rectifiers described herein, can comprise a diode, a synchronous rectifier, a transistor, such as a controllable FET, or other suitable device to provide such function.
  • Embodiments that position the starter 60 on the same terminal as the capacitor 20 , and isolate the capacitor from the battery 30 (by allowing only unidirectional current flow therebetween), can provide several benefits. For example, such embodiments can allow substantially only the power and current stored in the capacitor 20 to be provided to the starter 60 during a start event, reducing or eliminating the aforementioned affects of the battery resistance that may occur. Such isolation of functionality between the capacitor 20 and battery 30 can allow the capacitor 20 to supply power to quick or high power pulse devices, such as the starter 60 , and allow the battery 30 to contribute power to devices with medium or longer period demands.
  • Such embodiments can also prevent the state of charge and voltage of capacitor 20 from being reduced by the aforementioned lower voltage of the battery 30 , or from reaching a combined battery/capacitor equilibrium state of voltage.
  • the battery 30 may have an undesired, lower voltage because the battery has been accidently discharged, insufficiently recharged (for example, in a start/stop application), or is operating in a cold environment. The battery may have otherwise reached a lower state of charge due to lower charge acceptance.
  • the capacitor 20 can remain at a higher voltage and state of charge when the alternator 61 or another power supply is turned off, separate from the state of charge, voltage and capacity of the battery 30 .
  • Such isolation thus can also provide an overall higher energy to the starter 60 from the capacitor 20 , without the limiting effects of the battery 30 .
  • the aforementioned isolation of the battery 30 from the capacitor 20 and starter 60 can also reduce the load on the battery 30 during engine crank, thus improving the life of the battery 30 , for example, during start/stop applications.
  • these embodiments can improve vehicle start efficiency, and reduce the likelihood of the situation where the system can't provide sufficient power to the starter 60 to start the vehicle.
  • the discharge voltage at the alternator terminal 48 , and thus, of the battery 30 dropped to approximately 12.6V after the alternator 61 was turned off.
  • the increase in voltage and state of charge provided by using the isolated capacitor 20 and starter 60 may further enhance vehicle startup at low temperatures.
  • a battery's voltage may drop significantly more at a low temperature under load than that of a capacitor, resulting in low cranking power and efficiency.
  • a battery charged at approximately 15.0 volts (at approximately ⁇ 10 degrees F.) and discharged at approximately 500 amps results in a 2 second discharge voltage of approximately 9.5V.
  • a capacitor charged at approximately 15.0 volts (at approximately ⁇ 10 degrees F.) and discharged at approximately 500 amps results in a discharge voltage of approximately 13.5V.
  • a capacitor provides approximately 4 additional volts to a starter.
  • Such higher capacitor voltage in turn results in higher starter cranking power and motor velocity on the next engine crank and faster starting; thus the above example of 4 volts additional cranking power can provide approximately 40% faster crank speed.
  • a capacitor can store additional energy, even with respect to another capacitor, further enhancing the benefits of isolating the capacitor during vehicle startup.
  • C the capacitance
  • V the voltage.
  • a 400 farad capacitor at ⁇ 10° F. receiving a typical vehicle alternator 61 voltage supply of 15 volts (at that temperature) can store 45 kjoules of energy.
  • This is significantly more energy than a similar 400 farad capacitor at 160° F. receiving a typical vehicle alternator 61 voltage supply of 13.4 volts (at that temperature), which can only store 36 kjoules of energy.
  • Such increased energy corresponds to increased cranking power, and increased start reliability at cold temperatures.
  • Rectifier 63 can be any of a variety of sizes, depending on the application. In an example using a standard vehicle battery (approximately 12V), a 400 amp diode was employed. However, it is anticipated that diodes rated in a range from approximately 300 to 1000 amps may provide similar results.
  • FIG. 10 shows another embodiment of a three-terminal combined battery/capacitor energy storage device 500 , with many similar components as FIG. 9 .
  • the electronics schematically shown for the capacitor/battery combination device 500 can be implemented within the other three-terminal capacitor/battery combination devices described herein.
  • a current limiter 65 can be employed between the rectifier 63 and the starter terminal 50 . Any suitable current-limiting devices can be employed, such as a positive-temperature coefficient (PTC) thermistor, a self-resetting circuit breaker, an in-rush limiting resistor with a bypass switch, and the like.
  • the current limiter 65 can be employed to reduce the size of the rectifier 63 , or for other reasons.
  • PTC positive-temperature coefficient
  • the current limiter 65 can be configured to open (and thus increase its resistance) when the current to which it is exposed is high. For example, such a high current situation may be typical of an engine start event, when the capacitor 20 is being used to crank the starter 60 , as described above. When an increased a current is drawn from the battery 30 , the battery's operational life can be reduced. The current limiter 65 prevents or reduces current draw from the battery 30 to the starter 60 during the starter 60 crank, increasing the life of battery 30 . Additionally, by preventing or reducing the current draw from the alternator terminal 48 to the starter 60 through the rectifier 63 , the current limiter 65 can also protect the rectifier 63 from increased current levels. Such current protection to the rectifier 63 can allow it to be sized smaller.
  • a system that employs a current limiter 65 may reduce the size of the rectifier 63 to those rated between approximately 25 to 400 amps.
  • a smaller diode can allow the space envelope of device 10 to be smaller, or to be the same size, but with increased capacity of the battery and/or capacitor.
  • a current limiter 65 can be implemented in series with the other rectifiers described in other embodiments herein, to provide similar functionality.
  • FIG. 11 shows another embodiment of a three-terminal combined battery/capacitor energy storage device 600 , with many similar components as FIGS. 9-10 .
  • the electronics schematically shown for the capacitor/battery combination device 600 can be implemented within the other three-terminal capacitor/battery combination devices described herein.
  • a DC/DC converter 66 can be positioned between the alternator terminal 48 and the starter terminal 50 .
  • the DC/DC converter 66 can provide similar current management function as the aforementioned rectifier 63 , FET 64 , or rectifier 63 used in combination with a current limiter 65 .
  • the DC/DC converter 66 may also block the battery 30 from providing the entirety of the cranking current, and allow the capacitor 20 to be charged to a voltage greater than that of the battery 30 .
  • the DC/DC converter 66 may also charge the capacitor to different voltages depending on different environmental conditions; the capacitor may be charged to a higher voltage at lower temperatures, or lower voltage at higher temperatures.
  • a DC/DC converter can control in-rush current to the battery, to reduce battery temperature increases.
  • a DC/DC converter can also regulate the voltage of the capacitor to prevent an over-voltage condition.
  • FIG. 12 shows another embodiment of a three-terminal combined battery/capacitor energy storage device 700 , with an embodiment of the DC/DC converter 64 shown in FIG. 11 .
  • the electronics schematically shown for the capacitor/battery combination device 700 can be implemented within the other three-terminal capacitor/battery combination devices described herein.
  • the DC/DC converter 64 includes a boost controller 70 configured to control an FET 64 positioned between the ground terminal 49 and the rectifier 63 . It will be understood that other types of switching devices or transistors than FET 64 can be implemented.
  • the FET 64 and boost controller 70 can provide charge to the capacitor 20 through the rectifier 63 , to allow capacitor 20 to be charged to a voltage greater than battery 30 , while isolating battery 30 from current during starter crank.
  • An inductor 71 can be positioned between the alternator terminal 48 and the rectifier 63 , in parallel with the boost controller 70 and the FET 64 .
  • the inductor 71 can comprise a wire or bus bar with a saturable core surrounding it.
  • inductor 71 can comprise a saturable inductor.
  • the inductor 71 and the rectifier 63 can passively charge capacitor 20 to a voltage greater than battery 30 , while isolating battery 30 from current during starter crank. For example, when the voltage of capacitor 20 is lower than battery 30 (e.g., after a start event), the capacitor 20 can be charged passively through inductor 71 and rectifier 63 up to the battery voltage.
  • the boost controller 70 can activate FET 64 , allowing the capacitor 20 to actively charge, to a voltage greater than battery 30 .
  • FET 64 By including both the passive and active charging, a smaller and less expensive controller 70 and FET 64 can be implemented, and the charge time to the capacitor 20 is reduced.
  • the boost controller circuit shown in FIG. 12 can provide similar function as other DC/DC converters, but at lower complexity and cost.
  • FIG. 13 shows another embodiment of a three-terminal combined battery/capacitor energy storage device 800 , with many similar components as FIG. 12 .
  • the electronics schematically shown for the capacitor/battery combination device 800 can be implemented within the other three-terminal capacitor/battery combination devices described herein.
  • a second rectifier 73 can be positioned between the alternator terminal 48 and the starter terminal 50 , in parallel with the inductor 71 A and rectifier 63 .
  • inductor 71 A is not saturable.
  • the boost charger circuit shown in FIG. 13 can provide similar function as the circuit shown in FIG. 12 .
  • the rectifier 73 can charge the capacitor to a voltage approximately equal to that of the battery.
  • the boost charger can be turned on and raise the capacitor voltage to a set value above the battery voltage.
  • the boost charger can include an inductor 71 A (which is typically smaller than the inductor 71 of FIG. 12 ), the rectifier 63 (which is typically smaller than rectifier 73 ), FET 64 and boost controller 70 .
  • the boost charger can be of any suitable topology or implementation.
  • FIG. 14A shows another embodiment of a two-terminal combined battery/capacitor energy storage device 900 , with many similar components as FIGS. 9-13 .
  • the electronics schematically shown for the capacitor/battery combination device 900 can be implemented within the other two-terminal capacitor/battery combination devices described herein.
  • a first electronic switch 75 can be positioned to allow the capacitor 20 to be electrically connected to, and disconnected from, terminal 48 , or its associated terminal bus.
  • a second electronic switch 77 can be configured to allow the battery 30 to be electrically connected to and disconnected from terminal 48 , or its associated terminal bus.
  • the device 900 can include a rectifier 63 .
  • the rectifier 63 can be configured in parallel with switch 75 to allow the capacitor 20 to be charged while switch 75 is open, while preventing current flow in the opposite direction.
  • capacitor 20 can be passively charged through rectifier 63 from alternator 61 , regardless of the positioning of switches 75 and 77 .
  • a current limiter such as a thermistor, may be included in series with the rectifier 63 to reduce the current load experienced by the rectifier 63 and the battery 30 , as shown in FIG. 10 .
  • the switches 75 , 77 can be any of a number of suitable configurations, such as a semiconductor switch or a mechanical contactor. Suitable semiconductor switches include, for example, a various types of FETs or IGBTs. The switches 75 , 77 can be configured to be operated manually or automatically. Of course, it should be realized that some embodiments may have combinations wherein the rectifier 63 , or one or more of the electronic switches 75 , 77 are not used. In some embodiments, an optional DC/DC converter, such as those shown in FIGS. 11-13 , can be positioned between terminal 48 and capacitor 20 .
  • Switches 75 and/or 77 can be electronically controlled with a charge controller 74 . Any of a number of controllers described herein can be used to control switches 75 and/or 77 ; for example, the charge controller 74 can be a micro controller. Alternatively, the electronic switches 75 and/or 77 can be controlled by discreet logic.
  • the charge controller 74 can be provided with one or more of the following inputs: voltage sense from the capacitor (I vc ), voltage sense from the battery (I vb ), and/or current sense (I b ) from the battery output. Other inputs, such as temperature sensors, may also be implemented to provide additional functionality.
  • the charge controller 74 can provide one or more of the following outputs: output to control switch 75 (O a ) and/or output to control switch 77 (O b ). It will be understood that one or more of the aforementioned switching, sensing, and controlling functionality can be provided through one or more separate or integrally formed components. For example, a voltage sensor and switch may be combined in a single unit, and/or the switch and microcontroller can be a suitable relay that switches directly in response to an input signal, for example, without complex electronics.
  • FIG. 14B shows another embodiment of a two-terminal combined battery/capacitor energy storage device 1000 , with many similar components as FIGS. 9-14A .
  • the electronics schematically shown for the capacitor/battery combination device 500 can be implemented within the other two-terminal capacitor/battery combination devices described herein.
  • the embodiment shown in FIG. 14B is similar to that in FIG. 14A , but with different positioning of the rectifier 63 relative to switches 75 and 77 .
  • the rectifier 63 is connected to battery 30 , without intervening switch 77 .
  • device 10 can include the current limiter 65 as shown.
  • the functionality of the switches 75 and 77 in FIG. 14B can otherwise be similar to that described herein with reference to FIG. 14A or 15 .
  • FIG. 15 illustrates a substantially similar embodiment as FIG. 14A , but in a three-terminal combined battery/capacitor energy storage device 1110 .
  • the electronics schematically shown for the capacitor/battery combination device 1100 can be implemented within the other three-terminal capacitor/battery combination devices described herein.
  • FIG. 15 does not include some of the components shown in FIG. 14A , such as all the inputs, outputs, and switch 77 , but can be configured with these components, to provide similar functionality as the embodiments described herein with reference to FIG. 14A .
  • the embodiments in this section can improve vehicle start efficiency, and reduce the likelihood of the situation where the battery 30 can't provide sufficient power to the starter 60 to start the vehicle.
  • the battery 30 may have an undesired, lower voltage because the battery 30 has been accidently discharged, insufficiently recharged, is operating in a cold environment, or the battery 30 has otherwise reached a lower state of charge due to lower charge acceptance or lower capacity.
  • a battery may be discharged without sufficient periods of charging to fully recharge.
  • switch 75 can be opened, for example, through output signal O a from the charge controller 74 , to isolate the capacitor 20 from the battery 30 and terminal 48 .
  • switch 75 can remain open during the entire time the vehicle is turned OFF. However, it will be understood that some embodiments can allow switch 75 to close for a period of time when the vehicle is OFF, and still provide the improved starting function described herein.
  • the charge controller 74 can be configured to detect an event, for example, of the starter 60 cranking, by monitoring I b , the current out of the energy storage device 900 , the rate of change of the current output (dI/dt) and/or the change in voltage of the battery 20 (dV/dt), or a combination thereof.
  • switch 75 can be closed such that the capacitor 20 can supply power to the starter 60 .
  • the capacitor 20 was previously at least partially isolated from the battery open circuit voltage during periods when switch 75 was open, once switch 75 is closed during startup, the capacitor 20 can provide voltage to the starter 60 at a higher voltage than the battery open circuit voltage. Such higher voltage provided by the capacitor 20 can increase crank speed of the starter 60 , and improve the reliability with which the starter 60 will start a vehicle.
  • the charge voltage of the battery 30 and capacitor 20 while the alternator 61 is running may range between approximately 12 and 16V, with an average of approximately 14.4V.
  • the battery open circuit voltage may drop to a point between approximately 12 and 13V.
  • the capacitor 20 may remain at an increased open circuit voltage during the stop condition of the alternator 61 relative to that of the battery 30 , and can provide increased voltage and starting power during vehicle startup.
  • the battery 30 will contribute to a reduced portion of the starting current in parallel with the capacitor 20 , upon the closing of switch 75 and the use of the capacitor 20 during the starter 60 crank.
  • the voltage of the capacitor 20 when the alternator 61 is OFF may be reduced from that when the alternator 61 is running, based upon a voltage drop over the rectifier 63 .
  • an “ideal diode” circuit can be implemented. Such a circuit can monitor the voltage on both sides of switch 75 when the alternator 61 is on. The circuit can close switch 75 when the voltage on the alternator 61 side of switch 75 reaches a monitored level. Closing switch 75 can bypass the rectifier 63 and allow the voltage of the capacitor 20 to increase and approach that of the alternator 61 . In such an embodiment, when the alternator 61 is OFF, and switch 75 is opened, the capacitor 20 can remain at an open circuit voltage approximately the same as the voltage of the alternator 61 .
  • switch 77 can be opened, for example, by the charge controller 74 , to disconnect current being supplied from the battery 30 , and thus isolate the capacitor 20 and battery 30 .
  • switch 77 can be open during periods that switch 75 has been closed to isolate the capacitor 30 from the battery 20 , and allow only the increased capacitor voltage (and power) to crank the starter 60 during the aforementioned vehicle start. It may also be desired to supply power from the capacitor to one or more other vehicle loads, such as emergency lighting.
  • Switch 77 can be closed again, for example, when the capacitor voltage is approximately equal to the battery voltage or when the end of a cranking event has been detected.
  • isolation can reduce the load on the battery during engine crank, thus improving the life of the battery 30 , for example, during start/stop applications, and reducing cycling down effects.
  • Such isolation can also provide an overall higher energy to the starter 60 from the capacitor 20 , with the battery 30 at least partially isolated from the starting current.
  • Some embodiments can provide additional functionality in a hybrid vehicle, a vehicle with an internal combustion engine, or other vehicles equipped with a starter 60 .
  • some vehicles may include a starter 60 generator, with the ability to generate, and thus recuperate or regenerate, energy when the vehicle is braking.
  • a starter 60 generator with the ability to generate, and thus recuperate or regenerate, energy when the vehicle is braking.
  • many battery chemistries have a lower charge acceptance than a capacitor or ultracapacitor, and thus batteries may have lower efficiency than a capacitor in receiving and storing such regenerated braking energy.
  • the following embodiments can allow some or substantially all of the regenerated braking energy to be directed to the capacitor instead of the battery, to improve the efficiency in the regenerated braking and mitigate the limitations in charge acceptance that a battery may impart to the energy storage device.
  • switches 75 and 77 can be configured in a closed position.
  • both the battery 30 and the capacitor 20 can be charged by the alternator 61 to a voltage, ranging from 12-16V, or typically a 14.4V average in a typical vehicular application, as described above.
  • the charge controller 74 can detect that a regenerative braking event is initiated by detecting a significant increase in voltage relative to that provided by the alternator 61 .
  • the average voltage during a regenerative braking event may increase to a range between approximately 14.4V and 18V.
  • voltage during a regenerative braking event may increase up to any point within the voltage limitations in which the regenerative braking system is employed.
  • switch 77 can be opened to direct the regenerative braking energy only to the capacitor 20 .
  • Such capacitor isolation can allow the energy captured in the capacitor to be stored and then used in the next cranking event (for example, for a vehicle with start/stop functionality), to provide power to other auxiliary loads in the vehicle (such as lighting, air conditioning, cabin heating and the like), or to recharge the battery 30 by closing switch 75 .
  • switch 75 when the capacitor voltage is detected to be at a point indicating that the capacitor 20 has reached a full state of charge, switch 75 can be opened again and switch 77 can be closed, isolating the capacitor 20 from the system, and redirecting the regenerative braking energy to the battery 30 .
  • both switch 75 and switch 77 can be closed in a regenerative braking event, to allow the regenerative braking energy to be directed to both the capacitor 20 and battery 30 .
  • the regenerative braking energy and current may be split between the capacitor and battery.
  • switches 75 and 77 are in a closed position. In this mode of operation, both the battery 30 and the capacitor 20 can be charged from the alternator 61 with a charge voltage ranging from 12-16V, or a typical average charge voltage of 14.4V.
  • the charge controller 74 can detect that the vehicle is turned OFF when the alternator 61 is no longer delivering sufficient charging voltage. At this point, switch 75 can open to reduce the likelihood or prevent the capacitor 20 from discharging to the battery 30 and the other loads connected to the battery 30 (or terminal 48 ). Prior to being shut off from the charging voltage supply from the alternator 61 , the battery 30 generally maintains a reasonably high state of charge.
  • the state of charge of the battery 30 may drop at the point the alternator 61 is turned off.
  • the battery 30 is older, in a colder climate, or has been significantly discharged (such as in a start/stop application) without fully recharging prior to the alternator 61 being shut off, it is not uncommon for the battery's capacity to drop to a point ranging from 65-85% of its rated capacity.
  • a battery capacity is measured in amp hours with a typical battery having a capacity of 60 amp-hours, although many batteries have more or less capacity depending on their cost and application.
  • Some embodiments can help compensate for the aforementioned problems with battery state of charge, capacity and voltage that can occur after the battery 30 loses its supply of power from the alternator 61 .
  • switches 75 and 77 can be closed, allowing the capacitor 20 to supply energy to the battery 30 , and thus restoring all or a portion of the previously-lowered state of charge or open circuit voltage of the battery 30 .
  • Such a “trickle charge” event of the capacitor 20 to the battery 30 can occur at various times after shutting down the alternator 61 .
  • the length of time in which switch 75 is closed may vary, but generally ranges from approximately one hour to approximately four hours.
  • the trickle charge can be applied continuously, but can also be applied intermittently.
  • a trickle charge may be applied with a pulse-width-modulated (PWM) control, which may get rid of surface ion layers within the battery plates, allowing the battery to charge more quickly.
  • PWM pulse-width-modulated
  • a trickle charge may also be applied to the battery a single time while a vehicle is at rest, or several times over a given time period.
  • the amount of voltage in the capacitor 20 and battery 30 can be monitored during the trickle charge, to prevent the trickle charge from dropping the capacitor 20 and battery 30 voltage from dropping to a point below which the starter 60 cannot start (about 12V). If the voltage reaches such a low voltage point during a trickle charge, the charge controller 74 can re-open switch 75 , and retain enough voltage in the capacitor 20 to start the starter 60 .
  • FIG. 14A One or more of the aforementioned functions with respect to the system in FIG. 14A can be provided in the other two-terminal, two switch embodiment of FIG. 14B , or the three-terminal configuration shown in FIG. 15 with only switch 75 and the rectifier 63 .
  • An advantage of the embodiments shown in FIGS. 14A and 14B is that they are two-terminal designs, and may more easily replace existing two-terminal OEM batteries.
  • the three-terminal embodiment can provide some similar functionality, in a simpler application, for example, without switch 77 .
  • Such embodiments can separate the current flow from the capacitor 20 from that of the battery 30 , and allow the starter 60 to receive a higher voltage from only the capacitor 20 (when switch 75 is open).
  • Such embodiments can provide similar benefit as the embodiments shown in FIG.
  • switch 75 can be moved to an open position, to direct energy from regenerative braking to the capacitor 20 only, or switch 75 can be moved to the closed position, to direct energy from the regenerative braking to both the capacitor 20 and the battery 30 , to provide similar benefit as the embodiments shown in FIG. 14 and described herein in the section entitled “Recuperate braking energy.” Additionally, switch 75 can be moved to a closed position, to allow the capacitor 20 to trickle charge the battery, to provide similar benefit as the embodiments shown in FIG. 14A and described herein in the section entitled “Trickle charging the battery from the capacitor to reduce cycle-down effect.”
  • FIG. 16 shows another embodiment of a three-terminal combined battery/capacitor energy storage device 1200 , with many similar components as FIGS. 9-15 .
  • the electronics schematically shown for the capacitor/battery combination device 1200 can be implemented within the other three-terminal capacitor/battery combination devices described herein.
  • a current limiter 76 can be positioned between starter terminal 50 and alternator terminal 48 .
  • device 1200 can comprise a two-terminal device, similar to those other two-terminal devices described herein.
  • device 1200 can be configured without terminal 48 , and with the current limiter positioned between terminal 50 and battery 30 , and with the alternator 61 and car load 62 connected to terminal 50 .
  • the current limiter 76 can comprise a resistive bridge comprising one or more resistors.
  • the current limiter 76 can comprise one or more positive-temperature-coefficient resistors, a self-resetting circuit breaker, or another suitable current-limiting device.
  • the current limiter 76 can reduce the current draw into the battery 30 during the crank of a starter by capacitor 20 , similar to other embodiments of combined energy storage devices described herein, but with less components, lower cost, and increased reliability.
  • the resistance of current limiter 76 can be sized based upon the sizing, load profile, and inherent resistance of the battery 30 and the ESR of the capacitor 20 .
  • the current limiter 76 can be sized suitably large enough to provide the aforementioned benefits of reducing the current draw from the battery, without being so large that the recharge rate of the capacitor would be decreased below a useful value.
  • the current limiter should be sized so the system time constant (the resistance times the capacitance) is approximately 10 to 100 times larger than the duration of the peak power demand of the system. In most automotive applications, the peak power demand lasts between approximately 1 and 10 seconds so the current limiter should be sized such that the time constant of device 1200 is between approximately 10 and 1000 seconds. In some embodiments, the time constants for device 1200 can be between approximately 1 and 10,000 seconds.
  • a resistive bridge rated to 2000 W or more can be implemented within a combined battery/capacitor device that includes a battery with an open circuit voltage of 288V, and a capacitor in parallel with approximately 24 F of capacitance.
  • the current limiter 76 can be implemented in addition to one or more of the other embodiments described in FIGS. 9-15 .
  • FIG. 17 shows another embodiment of a two-terminal combined battery/capacitor energy storage device 1300 , with many similar components as FIGS. 9-16 .
  • the electronics schematically shown for the capacitor/battery combination device 1300 can be implemented within the other two-terminal capacitor/battery combination devices described herein.
  • device 1300 includes a network of rectifiers 63 , 73 , and 78 running in a string between two batteries 30 A and 30 B connected in parallel. Batteries 30 A and 30 B can be of approximately the same rated voltage and capacity.
  • the system of rectifiers 63 , 73 and 78 , and batteries 30 A and 30 B can be connected in parallel with capacitor 20 .
  • the embodiment of device 1300 shown in FIG. 17 can provide some of the benefits as those combination devices described herein that include a DC/DC converter or switched system, such as those shown in FIGS. 11-15 .
  • batteries 30 A and 30 B can work in parallel to power the car load 62 when the capacitor 20 is depleted below a certain level, such as at or below the rated voltage of batteries 30 A and 30 B.
  • the capacitor 20 can receive the power first, until the capacitor 20 reaches a certain level, such as twice the rated voltage of batteries 30 A and 30 B. Subsequently, the power can be used to recharge the batteries 30 A, 30 B.
  • the recharge of the batteries 30 A, 30 B is presumably at a lower effective rate, due to the batteries' higher internal resistance.
  • the embodiment of device 1300 in FIG. 17 can be implemented with only solid state components, and thus may be simpler with respect to a device with a DC/DC converter or switched system. Thus, the embodiment of FIG. 17 can be more reliable, and may be provided at a lower cost than some other hybrid battery/capacitor energy storage devices.
  • FIG. 18 shows another embodiment of a two terminal combined battery/capacitor energy storage device 1400 , with many similar components as FIGS. 9-17 .
  • the electronics schematically shown for the capacitor/battery combination device 1400 can be implemented within the other two-terminal capacitor/battery combination devices described herein.
  • capacitor 20 can comprise a capacitor bank with a plurality of capacitors 20 A- 20 F connected in series
  • battery 30 can comprise a battery bank with a plurality of batteries 30 A- 30 F connected in series.
  • the number of capacitors and the number of batteries implemented within energy storage device 10 can be the same, to provide better balancing between the batteries and capacitors as described further below.
  • a plurality of interconnects 80 A- 80 E can extend between the capacitor 20 and battery 30 , wherein each interconnect can include a first end connected between a corresponding adjacent pair of capacitors and a second end connected between a corresponding adjacent pair of batteries.
  • interconnect 80 A can include a first end 81 A connected at a point between capacitors 20 A and 20 B, and a second end 82 A connected at a point between batteries 30 A and 30 B, and so forth, for the remainder of the interconnects, batteries, and capacitors.
  • Interconnects 80 A- 80 E can comprise a wire, bus bar or other electrical connection.
  • Interconnects 80 A- 80 E can comprise a wire, bus bar, or other electrical connection, without other electrical components extending between adjacent capacitors and batteries.
  • the number of batteries and capacitors shown (six) and the number of interconnects (five) are for illustrative purposes.
  • the embodiment of device 1400 shown in FIG. 18 can provide balancing of the voltage of individual capacitors 20 A- 20 F within capacitor bank 20 relative to each other, and the overall output voltage of capacitor bank 20 .
  • the embodiment also can provide balancing of the voltage of individual batteries 30 A- 30 F within battery bank 30 relative to each other, and the overall output voltage of battery bank 30 .
  • Such balancing can reduce the differences between the voltages of the individual capacitors and/or batteries.
  • Such balancing can avoid certain capacitors or batteries being charged to a higher or lower voltage than other capacitors or batteries, which can have an impact on the service life of the capacitor 20 , battery 30 , or the hybrid energy storage device 1400 .
  • Such balancing can also prevent complete failure of the overall capacitor bank 20 or battery bank 30 in the event of a failure of one or more individual capacitors 20 A- 20 F and batteries 30 A- 30 F.
  • the balancing circuit in FIG. 18 is simpler, less expensive, and more robust than some balancing circuits that provide similar function, but with more complexity, such as switches, controllers, and the like.
  • DSP digital signal processor
  • ASIC application specific integrated circuit
  • FPGA field programmable gate array
  • a general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine.
  • a processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration.
  • a software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of non-transitory storage medium known in the art.
  • An exemplary computer-readable storage medium is coupled to the processor such the processor can read information from, and write information to, the computer-readable storage medium.
  • the storage medium may be integral to the processor.
  • the processor and the storage medium may reside in an ASIC.
  • the ASIC may reside in a user terminal, camera, or other device.
  • the processor and the storage medium may reside as discrete components in a user terminal, camera, or other device.
  • each of the modules comprises various sub-routines, procedures, definitional statements and macros.
  • Each of the modules are typically separately compiled and linked into a single executable program. Therefore, the following description of each of the modules is used for convenience to describe the functionality of the preferred system.
  • the processes that are undergone by each of the modules may be arbitrarily redistributed to one of the other modules, combined together in a single module, or made available in, for example, a shareable dynamic link library.
  • the invention disclosed herein may be implemented as a method, apparatus or article of manufacture using standard programming or engineering techniques to produce software, firmware, hardware, or any combination thereof.
  • article of manufacture refers to code or logic implemented in hardware or computer readable media such as optical storage devices, and volatile or non-volatile memory devices.
  • Such hardware may include, but is not limited to, field programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), complex programmable logic devices (CPLDs), programmable logic arrays (PLAs), microprocessors, or other similar processing devices.
  • Embodiments of the invention described herein can include any of a number of different software, hardware, firmware, electronic circuits, controllers, computers (including hand-held computing devices), microchips, integrated circuits, printed circuit boards, and/or other microelectronic component known or described herein, or combinations thereof, and methods related thereto, suitable to provide the functionality described herein. Additionally, the functionality described herein for managing a capacitor system can be provided through any suitable electronic, mechanical, pneumatic, hydraulic, and/or other components and/or systems, or combinations thereof, or methods related thereto.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Battery Mounting, Suspending (AREA)
  • Electric Double-Layer Capacitors Or The Like (AREA)
  • Charge And Discharge Circuits For Batteries Or The Like (AREA)
  • Secondary Cells (AREA)
  • Connection Of Batteries Or Terminals (AREA)
US13/797,358 2012-03-13 2013-03-12 Ultracapacitor and battery device with standard form factor Abandoned US20130266825A1 (en)

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US13/797,496 Abandoned US20130266826A1 (en) 2012-03-13 2013-03-12 Ultracapacitor/battery combination and bus bar system
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CN104285336A (zh) 2015-01-14
EP2826095A2 (fr) 2015-01-21
US20130266826A1 (en) 2013-10-10
JP6114374B2 (ja) 2017-04-12
JP2017162817A (ja) 2017-09-14
KR20140130232A (ko) 2014-11-07
US20130266824A1 (en) 2013-10-10
US20130264875A1 (en) 2013-10-10
WO2013138380A3 (fr) 2014-03-13
HK1204393A1 (en) 2015-11-13
WO2013138380A2 (fr) 2013-09-19

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