Description:FORM-2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See section 10 and rule 13)

Title: HIGH-CAPACITY SUPERCAPACITOR MODULE COMPRISING 36 SERIES-CONNECTED 3V, 5100F CELLS WITH ENHANCED ENERGY MANAGEMENT SYSTEM

APPLICANT DETAILS:
(a) NAME: WESTECHPOWER MANAGEMENT PRIVATE LIMITED
(b) NATIONALITY: Indian
(c) ADDRESS: Gat No. 162B, Tower Line Road, Triveni Nagar, Talawade, Pune –
411062, Maharashtra, India

PREAMBLE TO THE DESCRIPTION:
The following specification particularly describes the invention and the manner in which it is to be performed
HIGH-CAPACITY SUPERCAPACITOR MODULE COMPRISING 36 SERIES-CONNECTED 3V, 5100F CELLS WITH ENHANCED ENERGY MANAGEMENT SYSTEM

FIELD OF INVENTION:
The present invention generally relates to a supercapacitor module incorporating 36 series-connected supercapacitor cells, each rated at 3V and 5100F.

BACKGROUND OF THE INVENTION:
The following background discussion includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication expressly or implicitly referenced is prior art.
Today, with rapid growth of the electric, electronic, communication, computer, and automotive industries, and the development of portable devices, the importance of energy storage devices capable of repeatedly charging and discharging electricity is increasing. As such energy storage devices, capacitors have been developed in various forms depending on the type of electrolyte, whether the anode and cathode are symmetrical, and the charge storage characteristics. Among them, a supercapacitor is which uses a pair of charge layers (electric double layers) having different signs at the interface between the electrode and the conductor and the electrolyte solution impregnated therein. The supercapacitor is generally having two electrodes of a positive electrode and a negative electrode impregnated with an electrolyte, and a separator made of a porous material interposed therebetween to allow only ion conduction and to prevent insulation and short circuit. For example, JP2010524200A discloses a mechanism and a manufacturing method for realizing a high-efficiency energy storage capability of a supercapacitor by using a bipolar electrode to realize a single higher voltage. Then, it will be explained that the combination of bipolar electrodes can be applied to various power demands. A supercapacitor having a high operating voltage can be manufactured in units of elements by connecting a plurality of electrodes in series in a single element of the supercapacitor. Similarly, a supercapacitor module with a high operating voltage can be made by connecting a plurality of elements in a single housing in series in an intra-housing. If a high-voltage supercapacitor can be put in a single unit or module in this way, the range of high-voltage applications such as automobiles, power tools, machine tools, and automation is expanded.
Further, CN214012755U discloses a large-capacity super capacitor module, which comprises a shell, and a plurality of cooling fins, a connecting frame, a fixed block and capacitors which are arranged in the shell, wherein the capacitors are arranged in a rectangular array to form a capacitor module; the two vertical side surfaces of the capacitor module are connected with connecting frames, the connecting frames are formed by frame parts, and the frame parts are spliced and fixed; the upper end and the lower end of the connecting frame are both provided with fixed blocks, and the fixed blocks are internally provided with wiring harnesses for a circuit in a penetrating way; and radiating fins are arranged on two sides of the fixed capacitor.
In another document, KR20130093698A discloses a module for a high-capacity super capacitor having a thermal insulation function is provided to form a frame in a dual structure, thereby increasing insulating effects. A frame is inserted into the insertion groove of a connection rod. A support is fastened in the lower part of a housing. A cover is fastened in the upper part of the housing. A first forming part (131) forms fitting parts (123) in one side and the other side end parts. A second forming part (132) is installed in the internal space of the first forming part.
However, the existing art does not provide improved energy storage capacity and power density capacitor suitable for applications requiring rapid charge and discharge cycles. The present invention provides high energy storage capacity and power density capacitor suitable for applications requiring rapid charge and discharge cycles.

OBJECT(S) OF THE PRESENT INVENTION:
The primary objective of the present invention is to overcome the drawback associated with prior art.
Another object of the present invention is to provide an improved energy storage capacity and power density capacitor suitable for applications requiring rapid charge and discharge cycles.

SUMMARY OF THE PRESENT INVENTION:
In an aspect the present invention provides a supercapacitor module comprising:
a) a 36 series-connected supercapacitor cells rated at 3V and 5100F, achieving a nominal voltage of 108V and an equivalent capacitance of approximately 141 F; and
b) a capacitor management system configured for voltage and temperature monitoring along with active and passive supercapacitor cells balancing;
wherein the capacitor management system has an integrated electronic control system that continuously measures individual supercapacitor cells voltages with ±0.5mV accuracy, preventing overvoltage (>3.1 V) conditions through automatic charge redistribution and circuit protection.
In an embodiment, the capacitor management system monitors temperature of supercapacitor cells through plurality of thermistors having negative temperature coefficient to detect temperature in range from - 40°C to 85°C.
In an embodiment, the capacitor management system is configured to performs active cell balancing by transferring energy between cells by a plurality of DC-DC converters which dynamically adjust a balancing current based on voltage disparities.
In an embodiment, the capacitor management system performs a passive cell balancing by implementing a precision resistive bypass circuits which becomes automatically activates when voltage differentials exceed 50 mV.
In an embodiment, the module designed for a cycle life exceeding 5,00,000 cycles within the specified operational voltage range.
In an aspect the present invention provides a method of operation of supercapacitor module, comprising:
a) connecting a 36 supercapacitor cells in series, where the series connection gives a nominal voltage of 108V and an equivalent capacitance of approximately 141 F; and
b) monitoring voltage and temperature in the supercapacitor cells and performing balancing of supercapacitor cells by a capacitor management system;
wherein the capacitor management system has an integrated electronic control system that continuously measures individual supercapacitor cells voltages with ±0.5mV accuracy, preventing overvoltage (>3.1 V) conditions through automatic charge redistribution and circuit protection.

BRIEF DESCRIPTION OF DRAWINGS:
The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, explain the disclosed principles. The reference numbers are used throughout the figures to describe the features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and regarding the accompanying figures, in which
Figure 1: illustrates the capacitor module of the present invention.
Figure 2: illustrates the three-dimensional top view of module of the present invention.

DETAILED DESCRIPTION OF THE INVENTION:
In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example, in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the specific forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the disclosure.
The terms “comprises”, “comprising”, “includes”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device or method that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.
The present invention provides an improved energy storage capacity and power density capacitor suitable for applications requiring rapid charge and discharge cycles.
In an aspect the present invention provides a supercapacitor module comprising:
a) a 36 series-connected supercapacitor cells rated at 3V and 5100F, achieving a nominal voltage of 108V and an equivalent capacitance of approximately 141 F; and
b) a capacitor management system configured for voltage and temperature monitoring along with active and passive supercapacitor cells balancing;
wherein the capacitor management system has an integrated electronic control system that continuously measures individual supercapacitor cells voltages with ±0.5mV accuracy, preventing overvoltage (>3.1 V) conditions through automatic charge redistribution and circuit protection.
In an embodiment, the capacitor management system monitors temperature of supercapacitor cells through plurality of thermistors having negative temperature coefficient to detect temperature in range from - 40°C to 85°C.
In an embodiment, the capacitor management system is configured to performs active cell balancing by transferring energy between cells by a plurality of DC-DC converters which dynamically adjust a balancing current based on voltage disparities.
In an embodiment, the capacitor management system performs a passive cell balancing by implementing a precision resistive bypass circuits which becomes automatically activates when voltage differentials exceed 50 mV.
In an embodiment, the module designed for a cycle life exceeding 5,00,000 cycles within the specified operational voltage range.
In an aspect the present invention provides a method of operation of supercapacitor module, comprising:
a) connecting a 36 supercapacitor cells in series, where the series connection gives a nominal voltage of 108V and an equivalent capacitance of approximately 141 F; and
b) monitoring voltage and temperature in the supercapacitor cells and performing balancing of supercapacitor cells by a capacitor management system;
wherein the capacitor management system has an integrated electronic control system that continuously measures individual supercapacitor cells voltages with ±0.5mV accuracy, preventing overvoltage (>3.1 V) conditions through automatic charge redistribution and circuit protection.
In an embodiment, the capacitor module has following electrode composition:
Each cell utilizes an advanced electrode composition that achieves higher energy density with amount of activated Carbon: 81.2%, amount of conducting Carbon: 13.8% and the binders comprises carboxymethyl cellulose (CMC) with amount of 3.9% plus an additional binder (potato starch or styrene-butadiene rubber) with amount of 1.1%.
In an embodiment, the electrolyte used in the present invention is an optimized acetonitrile-based electrolyte with pyrrolidinium-based salt conducive to enhancing both energy density and power capabilities. In the present invention, the electrolyte is optimized with 0.7 mol to 1.2 mol of pyrrolidinium salt in acetonitrile, providing an ideal concentration range that balances ionic conductivity with stability to enhance both energy density and power capabilities.

In an embodiment, the capacitor module of the present invention has enhanced energy management system. The integrated management system has advanced voltage and temperature monitoring which prevents over-voltage and over-temperature conditions, ensuring the safe operation of the module. The enhanced energy management system's technical advantages are achieved through integrated high-precision voltage sensors across all cells, active cell balancing circuits, and strategically placed thermal sensors, which together provide real-time monitoring and prevention of over-voltage and over-temperature conditions for safe operation.
In an embodiment, the energy management system includes the active and passive cell balancing which enhances the overall performance while extending the cycle life of the supercapacitor cells through efficient charge redistribution. The technical advantage is achieved through hybrid cell balancing that combines active balancing circuits for energy transfer between cells, passive resistive networks to dissipate excess energy, real-time voltage monitoring to identify imbalances early, and adaptive timing control that optimizes when balancing occurs—all working together to minimize voltage disparity, reduce thermal stress, and extend cycle life.
In an embodiment, the supercapacitor module has over 5,00,000 cycles between operating voltages of 54V and 108V, thus allowing for extended usage in practical applications.
In an embodiment, the supercapacitor module has the following performance characteristics:
The module is designed to deliver:
Maximum stored Energy: Targeting over 228 Wh.
High Power Capability: 365 KW (Efficient performance at elevated current rates - specific metrics to be established via testing).
ESR – Less than 8 mΩ.
Wide Operating Temperature Range: -40°C to 65°C.
In an embodiment, the supercapacitor module has the following manufacturing methods
Dry electrode making method followed by lamination.
Controlled drying, calendaring, and jelly-roll winding of the electrode assembly.
Inert atmosphere cell assembly followed by electrolyte filling and sealing to ensure high performance and safety.
In an embodiment, the supercapacitor module has the extraordinary cycle life exceeding 500,000 cycles within the specified operational voltage range (54V-108V) is achieved through a combination of:
Advanced electrode composition with precisely optimized ratios (81.2% activated carbon, 13.8% conducting carbon, and 5% binders including CMC and additional binders) that enhances structural stability during cycling;
Specialized electrolyte formulation using acetonitrile with pyrrolidinium-based salt (0.7-1.2 mol concentration) that minimizes electrolyte degradation over repeated cycling;
Enhanced energy management system featuring:
High-precision voltage monitoring across all 36 cells,
Hybrid cell balancing combining both active and passive balancing mechanisms,
Real-time temperature monitoring, and
Adaptive timing control for balancing operations.
In an embodiment, the supercapacitor module is manufactured by methods including dry electrode fabrication, controlled calendaring, jelly-roll winding, and inert atmosphere assembly that ensure consistent cell quality and minimal internal degradation mechanisms. These technical elements work synergistically to dramatically reduce voltage disparity between cells, minimize thermal stress, and prevent degradation mechanisms that typically limit cycle life in conventional supercapacitor designs.

, Claims: We Claim:

1. A supercapacitor module comprising:
a) a 36 series-connected supercapacitor cells rated at 3V and 5100F, achieving a nominal voltage of 108V and an equivalent capacitance of approximately 141 F; and
b) a capacitor management system configured for voltage and temperature monitoring along with active and passive supercapacitor cells balancing;
wherein the capacitor management system has an integrated electronic control system that continuously measures individual supercapacitor cells voltages with ±0.5mV accuracy, preventing overvoltage (>3.1 V) conditions through automatic charge redistribution and circuit protection.
2. The supercapacitor module as claimed in claim 1, wherein the capacitor management system monitors temperature of supercapacitor cells through plurality of thermistors having negative temperature coefficient to detect temperature in range from - 40°C to 85°C.
3. The supercapacitor module as claimed in claim 1, wherein the capacitor management system is configured to performs active cell balancing by transferring energy between cells by a plurality of DC-DC converters which dynamically adjust a balancing current based on voltage disparities.
4. The supercapacitor module as claimed in claim 1, wherein the capacitor management system performs a passive cell balancing by implementing a precision resistive bypass circuits which becomes automatically activates when voltage differentials exceed 50 mV.
5. The supercapacitor module as claimed in claim 1, wherein the module designed for a cycle life exceeding 5,00,000 cycles within the specified operational voltage range.

6. A method of operation of supercapacitor module as claimed in claim 1, comprising:
a) connecting a 36 supercapacitor cells in series, where the series connection gives a nominal voltage of 108V and an equivalent capacitance of approximately 141 F; and
b) monitoring voltage and temperature in the supercapacitor cells and performing balancing of supercapacitor cells by a capacitor management system;
wherein the capacitor management system has an integrated electronic control system that continuously measures individual supercapacitor cells voltages with ±0.5mV accuracy, preventing overvoltage (>3.1 V) conditions through automatic charge redistribution and circuit protection.