What Is one Ultracapacitor?

Ultracapacitors, likewise known together electrochemical double-layer capacitors (EDLCs), are electrochemical capacitors the possess an uncommonly high power and energy density when compared with classic capacitors—typically several orders of magnitude greater than a high-capacity electrolytic capacitor. Most ultracapacitors room rated in Farads, and also individual cells can typically be uncovered in the 100F to 500F range, though they can extend greater or lower. Depending upon the applications needed, ultracapacitors may be supplied as battery replace instead instead or allow smaller, more economical battery selection. Ultracapacitors have low equivalent collection resistance (ESR), permitting them come deliver and also absorb high currents. Their mechanical (rather 보다 chemical) charge-carrier mechanisms permit their long, predictable life with a smooth performance change over time.

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Ultracapacitors room not a new technology. The ultracapacitor impact was very first noticed in 1957 through General electric engineers trying out with gadgets using porous carbon electrodes. The was believed that the energy was save in the carbon pores and also exhibited "e;exceptionally high capacitance,"e; return the reason was unknown at that time.

General electric did not instantly follow up on this work, and also the modern-day version that the gadgets was eventually occurred by researchers at typical Oil that Ohio in 1966, after lock accidentally rediscovered the effect while working on experimental fuel cabinet designs. Your cell style used 2 layers of set off charcoal be separated by a thin porous insulator, and also this mechanical design remains the communication for many ultracapacitors today. They very first appeared together a low-energy, long-life power back-up for consumer electronic devices like VCRs.

The past decade has actually seen substantial developments in ultracapacitor material science, construction, and also manufacturing techniques, which has actually made them highly desirable products, particularly for mission-critical applications. In recent years, these devices have found their method into customer electronics, commercial products, and also automotive applications. Today, the ideal ultracapacitors are incredibly high-power gadgets with strength densities of as much as 20kW/kg. Compact in size (small-cell ultracapacitors are often no bigger 보다 the size of a postage stamp), they deserve to store much much more energy than typical capacitors and can relax that energy easily or slowly. They have long life and are draft to critical the life time of the end product.

How perform Ultracapacitors Work?

Generally, capacitors are constructed with a dielectric (insulator) placed between two steel plates that serve as conductors; energy is save when, during the charging process, electrons leaving one plate and also accumulate ~ above the other, structure a confident charge top top one plate and also a negative charge on the various other as the dielectric prevents the negatively fee electrons from return to the positively charged plate. This charge separation create a potential between the 2 plates, which have the right to be harnessed in an external circuit. The complete energy gathered in this fashion is a mix of the variety of charges stored and also the potential between the plates. The number of charges stored is basically a function of the size and material properties of the plates, while the potential in between the plates counts on the dielectric material used.

Ultracapacitors, by contrast, usually do no have any type of dielectrics yet rather make use of a slim coating top top the steel plates to keep the confident and an adverse charges in place. The porous nature that the carbon coating supplied in this "e;electric dual layer"e; provides the bowl a larger surface area, which enables for a higher number of fees to be stored on them. The carbon coating supplied is additionally much thinner than any kind of dielectric supplied in a timeless capacitor, which method that the distance in between the separated fees is lot smaller in ultracapacitors. Combined, this very tiny charge separation and increased plate surface ar area provide ultracapacitors a much higher energy thickness than that of traditional capacitors.

Ultracapacitor fee Separation


To fee them, ultracapacitors room submerged in one electrolyte consist of of optimistic and an adverse ions liquified in a solvent. There room two varieties of electrolytes provided by ultracapacitor manufacturers: One is water-soluble, and also the other is non-water-soluble. The non-water-soluble electrolyte boosts the resist voltage per cell contrasted to that of a water-soluble electrolyte, producing a greater energy density. Tecate team cells space made through non-water-soluble electrolytes.

How room Ultracapacitors Constructed?

The specifics of ultracapacitor building are dependency on the manufacturer and the plan application. The products may likewise differ slightly between manufacturers or early to certain application requirements. The commonality among all ultracapacitors is the they covers a optimistic electrode, a an unfavorable electrode, a separator in between these 2 electrodes, and also an electrolyte pour it until it is full the porosities the the two electrodes and also separators.

Internal cell Construction


Most manufacturers have adopted a cylindrical construction method for their ultracapacitors; however, there are still commodities on the market that use a prismatic design. Tecate’s commodities use a cylindrical building method. The cells are constructed from caused carbon particles, which are combined with a binder and then deposit on aluminum foil. In this method, as displayed in the complying with figure, the electrodes space wound right into a jellyroll configuration very comparable to an aluminum electrolytic capacitor. The electrodes have actually foil extensions that are then welded to the terminals to permit a present path come the outside of the capacitor.

External cabinet Construction


What Is Equivalent collection Resistance (ESR)?

Ultracapacitors endure some level of inner resistance, described as "e;equivalent collection resistance (ESR),"e; i m sorry occurs when the materials used in the ultracapacitor resist the passage of the charges from one plate come another. The lot of ESR varies depending on the particular characteristics (materials used, quality, etc.) of the ultracapacitor.

ESR (referred to together Rs in the chart below) is the key contributor to strength loss during ultracapacitor charging and discharging. The other contributing factors are parallel resistance (Rp), capacitance (C), and also the series inductor (Ls).

First-Order-Equivalent Circuit


Since Rp is always much bigger than Rs, it have the right to be ignored. Also, since of the porous product used ~ above the electrodes of ultracapacitors, they exhibit non-ideal behavior, which causes the capacitance and also resistance to be dispersed such the the electrical solution mimics infection line behavior. Therefore, the is important to use a more general circuit, as shown in the figure below, to stand for the real electrical an answer and ESR effect.

Ladder Network


What room Ultracapacitor benefits and Limitations?

Ultracapacitors have several distinct advantages, the very first of i m sorry is their high energy storage. Ultracapacitors own energy thickness that is several times greater than that of timeless capacitors. Compared with batteries, they likewise possess a low inner resistance (ESR), furthering your high power-density capabilities. Ultracapacitors are likewise capable of performing at short temperatures. Tecate Group’s ultracapacitors, v their usage of patented technology, are qualified of delivering power down come -40°C v minimal effect on efficiency. And finally, ultracapacitors have an extremely fast charge and discharge rates. Since they achieve charging and discharging v the absorption and release of ions, high present charging and also discharging is possible without any damage come the parts.

Ultracapacitors do have a couple of limitations. They have actually low per-cell voltage, typically roughly 2.7V, which way that any type of higher-voltage applications call for the cells to be linked in series. Also, due to the fact that of their time constant, ultracapacitors room not perfect for use in AC or high-frequency circuits.

How perform Ultracapacitors differ from Batteries?

Portable applications and also digital technology have outpaced timeless chemical battery technology. A typical symptom of insufficient battery performance is the ratio of time the appliance is in usage versus the appliance recharge time. One more nuisance is when a battery has to be replaced prematurely together it will certainly no longer host a charge. In these situations, making use of batteries in conjunction v ultracapacitors can improve overall system performance and also extend battery life.

One factor batteries often tend to require premature instead of is that, as soon as a explode of energy is needed for an application, the high resistance the a chemistry battery can cause the battery voltage come collapse. Ultracapacitors, in contrast, have actually a low internal resistance that permits them to provide such explode of energy with no damages to the ultracapacitor. This is because, unlike batteries, i beg your pardon discharge in ~ a fairly continuous rate, ultracapacitors act very likewise to timeless capacitors and also will drop their voltage as they discharge your stored energy. When they are used in conjunction with batteries, ultracapacitors eliminate the instantaneous energy demands put on batteries, and this subsequently extends battery run time and prevents decreasing charge volume as the battery ages.

Ultracapacitor Discharge Curve


Also unequal batteries, ultracapacitors are maintenance-free and also operate end a large temperature range. They have the right to be charged and also discharged at the very same rate, while battery are restricted by your slower charge rate.

Ultracapacitor performance vs. Battery/Conventional Capacitor Performance


As have the right to be seen in the graph above, ultracapacitors reside in between batteries and also conventional capacitors in regards to energy and power density. Lock are generally used in applications where batteries come up quick when it involves high power/life and also conventional capacitors cannot be used since of a lack of energy. Ultracapacitors market high power density along with adequate energy density for most short-term, high-power applications. The chart below offers a additional comparison that the various technologies.

Ultracapacitors vs. Batteries and Conventional Capacitors


What Is the Difference in between Power and Energy?


Although the is common to usage the terms power and also energy interchangeably, they space not the same. Energy is the amount of occupational that deserve to be done, while power is the rate at which energy is supplied to do that work. In various other words, power is the lot of power used every unit of time. The two are related according to the complying with formula:

Power * Time = Energy

As deserve to be checked out in the chart below, ultracapacitors, traditional capacitors, and batteries fall in various places on the scale of strength versus energy density. Power density refers come how quickly a machine can discharge that energy, if energy thickness refers to how much energy a device contains. Batteries have actually low strength density but high power density, an interpretation they have actually a lot of of energy that it s okay discharged slowly. Traditional capacitors, ~ above the other hand, have actually high power density but low energy density, meaning they have actually less energy however it can be discharged much more quickly. Ultracapacitors fall somewhere in the middle, with high strength density and medium energy density.

Power density vs. Energy Density


What room the key Applications because that Ultracapacitors?

Ultracapacitors offer plenty of benefits, consisting of (1) reliable interim power also if the main power resource fails or fluctuates, (2) high-energy storage from low-power sources to allow support because that high power loads, and (3) peak-power supply to tons while drawing average power from sources. This means that using ultracapacitors in any type of application reduces the size and weight the the main power source, boosts run time and also battery life (particularly at cold temperatures), enables an ext power-hungry functions to be used an ext often, protects against accidental strength loss or fluctuations/interruptions, removes the need for product replacement, and also is environmentally friendly.

Applications benefiting indigenous ultracapacitor features include regenerative braking and other quick-charge scenarios such as those in toys and tools. Some applications are well suitable for combination battery/ultracapacitor systems, where designs deserve to be optimized to avoid battery oversizing for strength demands. Examples incorporate applications in customer electronics such as digital cameras, in which an inexpensive alkaline battery is merged with one ultracapacitor, and automotive applications such together hybrid strength trains.

What Is End-of-life and also Failure setting for one Ultracapacitor?

In general, ultracapacitors perform not have a difficult end-of-life failure as carry out batteries. Their finish of life is defined as when the capacitance and/or ESR has degraded past the application’s needs.

Ultracapacitor failure can be caused by place ultracapacitors in "e;abuse"e; conditions, which encompass over-voltage, over-temperature, and also mechanical stress and anxiety conditions. Over-voltage and also over-temperature conditions can result in a ns of capacitance, enhanced ESR, bulging, and also venting. Mechanical stress conditions can an outcome in deformation, damaged leads, and also increased ESR.

Failure under Abuse Conditions


What Is the Self-discharge and Leakage current of an Ultracapacitor?

Over time, fee ultracapacitors without a load gradually lose your charge. "e;Self-discharge"e; is the voltage drop a fee ultracapacitor cabinet experiences after a set duration of time there is no a load.



Ultracapacitors call for a present to store them charged. The leakage current is the stable parasitic existing needed to hold an ultracapacitor on fee at a rated voltage. The value required for the leakage current is voltage- and also temperature-dependent.

Leakage Current


Why usage Series/Parallel combine of Ultracapacitors?

An ultracapacitor cell have the right to only stand up to low voltages. In general, if cells room operated over their rated voltages for a long duration of time, their life is reduced. This is a result of the electrolyte breaking down after exposure to high voltage. The amount of damages varies based on the voltage and the amount of time the cell is exposed come the over-voltage condition. Thus, sometimes spikes above rated voltage will certainly not immediately influence an ultracapacitor, but prolonged high-voltage provides will.

The voltage rating of Tecate’s ultracapacitor cell is 2.7V or 3.0V. This higher-than-usual rating is mainly acquired from the electrochemical stability of the electrolyte and electrode materials. The Tecate family of products uses an essential electrolyte. The crucial advantage the an essential electrolyte versus various other (aqueous) electrolytes is its higher voltage stability. Yet also the higher-than-usual voltage rating the Tecate’s ultracapacitor cells is not enough to meet the compelled voltage of most applications.

Placing multiple ultracapacitor cell in series overcomes this limitation. This method that ultracapacitors rated for greater voltages need to be do of matched, series-connected separation, personal, instance capacitors, lot like series-connected cell in higher-voltage batteries. Depending on the required energy, there can be a have to then ar multiple cell in parallel. Once ultracapacitor cells are put in series or parallel, they reaction very similarly to traditional capacitors. Listed below is a an introduction of how key attributes respond as soon as multiple cells are placed in series/parallel formation:


Series connection: once placing cell in series, the as whole voltage is increased directly by the number of cells in series.

Example: 4 cell (rated in ~ 2.7V each) associated in collection will have a preferably voltage that 10.8V.

Parallel connection: Placing cells in parallel will not influence the voltage.

Example: 4 cells (rated at 2.7V each) connected in parallel will have a preferably voltage the 2.7V.


Series connection: once placing same-value cells in series, the system capacitance is decreased by the number of cells put in collection based ~ above the following formula: Csys = Ccell/n.

Example: 4 cells (rated in ~ 10F each) connected in collection will have actually a capacitance of 2.5F.

Parallel connection: put same-value cells in parallel will increase the in its entirety system capacitance directly by the variety of cells inserted in parallel.

Example: 4 cell (rated at 10F each) associated in parallel will have actually a capacitance of 40F.


Series connection: as soon as placing same-value cells in series, the as whole system ESR will increase straight by the variety of cells inserted in series.

Example: 4 cell (DC ESR 75 mΩ each) linked in collection will have a total ESR that 300 mΩ.

Parallel connection: placing same-value cells in parallel will decrease the overall system ESR proportionally come the variety of cells placed in parallel, according to the following formula: ESRsys = ESRcell/n.

Example: 4 cell (DC ESR 75 mΩ each) connected in parallel will have a full ESR the 18.75 mΩ.

Leakage Current

Series connection: place same-value cell in collection will not impact the leakage current.*

Example: 4 cell (each with a leakage current of 0.03mA) connected in series will have a total leakage current of 0.03mA.

Parallel connection: put same-value cells in parallel will rise the all at once leakage current directly by the variety of cells inserted in parallel.*

Example: 4 cell (each with a leakage existing of 0.03mA) linked in parallel will have a complete leakage present of 0.12mA.

*It must be detailed that this does no take into account any leakage existing induced as a an outcome of cell balancing. In the case of passive balancing, the leakage current will be dominated by the bypass resistor value.

Why execute Ultracapacitors need Balancing, and What room the Balancing Methods?

For most applications, a solitary ultracapacitor cabinet at short voltage is not really useful, for this reason multiple ultracapacitor cells inserted in series are forced most that the time. Since ultracapacitor cells have actually a tolerance difference in capacitance and leakage current, there will always be one imbalance in the cell voltages of an ultracapacitor series stack. The is essential to ensure the the separation, personal, instance voltage the any single ultracapacitor cabinet does no exceed its maximum recommended functioning voltage, together this could result in electrolyte decomposition, gas generation, ESR increase, and ultimately lessened life.

This voltage imbalance is instantly dominated through the capacitance difference between the ultracapacitor cells due to the fact that a cell v a reduced capacitance will charge to a greater voltage in a series string. Because that example, if two ultracapacitor cell of 10F every are linked in series, v one cell at +20% of nominal capacitance and the various other at -10%, climate the highest feasible voltage for each ultracapacitor cell can be calculated together follows:

Vcap1=Vsupply x (Ccap1/(Ccap1 + Ccap2))

Assuming Vsupply=5.4V

Vcap1=5.4 x (12/(12+9))


A voltage of 3.08V is too high for a solitary ultracapacitor cell; thus, series-connected ultracapacitor cells require a proper cell-balancing plan to ensure the no cabinet sees a higher-than-rated voltage.

Ultracapacitor Balancing Scheme


When one ultracapacitor collection stack is on charge for a duration of time, leakage existing may also impact the voltage distribution amongst the cells. In this case, a cell with a greater leakage existing will go to a lower voltage, distributing the remaining voltage amongst the various other cells and resulting in one over-voltage condition. Ideal cell balancing can remove this imbalance.

There are two balancing schemes to tackle uneven voltage distribution and also ensure a properly well balanced ultracapacitor module: passive balancing and energetic balancing.

Passive Balancing: One an approach to compensate because that variations in individual cells is to location a same-valued bypass resistor in parallel through each cell, size to dominate the full cell leakage current. This properly reduces the sport in tantamount parallel resistance in between the cells, i m sorry eliminates distinctions in the leakage current. Because that example, if the cells have an mean leakage present of 10uA +/- 3uA, using a 1% resistor that will certainly bypass 100uA in parallel to every cell will readjust the median leakage current to 110uA +/- 4uA and also decrease the sport in leakage existing from 30% to 3.6%. Having the same-value resistor in parallel through all cell also permits the cell with greater voltages to discharge v the parallel resistor in ~ a greater rate than the cell with reduced voltages. Together, these effects aid to distribution the full voltage evenly across the entire series of ultracapacitor cells.

Passive cabinet Balancing


Passive voltage balancing is just recommended because that applications that do not routinely charge and also discharge the ultracapacitor cells and that deserve to tolerate the added load present of the balancing resistors. If this technique is appropriate, the balancing resistors have to be selected to give second current circulation of at least 10 time the worst-case cell leakage current. Higher ratios have the right to be provided to balance the cells faster, if the series can pardon the increased current load. As soon as the device is balanced, the time it bring away to save the mechanism in balance is less of an concern unless the is gift severely cycled.

Active cabinet Balancing


Active Balancing: An active balancing circuit works by forcing the voltage in ~ the nodes of series-connected cell to stay below a fixed referral voltage. Active circuits typically draw much reduced levels of present in a steady state and only require larger currents when the cell voltages go out of balance. These qualities make energetic voltage-balancing circuits appropriate for applications the charge and also discharge the cell frequently, as well as those v a finite power source.

How walk Temperature influence Ultracapacitors?

One that the main benefits of ultracapacitors is their large temperature range. The results extreme temperatures have actually on ultracapacitor cells relies on whether the temperature is exceptionally high or extremely low. Operation at very high temperatures will alleviate the life the the cells, while operation at very low temperature will boost the interior resistance of the cells.

Effect of incredibly Low temperature on Ultracapacitors


What room the measures to execute a constant Current Discharge Test?

A constant current discharge test deserve to be valuable for customer review of an ultracapacitor module prior to application testing. Please note that, for security reasons, Tecate stores every one of its ultracapacitor cells and modules in a discharged state and also recommends that customers totally discharge any type of ultracapacitors that will certainly not be automatically installed right into equipment.

Required Equipment

Ultracapacitor module Bidirectional strength supply (supply/load) or separate power supply and programmable load (capable of giving a constant current) Voltage vs. Time measurement/recording machine (digital scope or other data acquisition) existing vs. Time measurement/recording machine (optional if the power supply and load settings are trustworthy) collection the strength supply to the suitable voltage and current limits, and turn the supply output off. The current limit have the right to be anything at or much less than the preferably rated current for the lowest-rated cabinet in the series. The voltage border is the maximum cabinet voltage times the number of cells in the series. Every cell’s voltage have to be minimal to the best rated voltage for the lowest-rated cabinet in the series. Having actually preset the current and also voltage limits, connect the ultracapacitor module come the strength supply. Cooling air may be forced to store the module within operation temperature limits, depending upon the check current and also duration. Connect the voltage and also current measuring/recording devices.


v the power supply preset and the ultracapacitor module connected, revolve the supply calculation on. Charge the module in ~ the proper current come the ideal voltage.


Note: If you space using a separate programmable load instead of an integrated bidirectional strength supply, disconnect the charging strength supply before discharging. Do not merely turn it turn off or readjust its collection points, as countless supplies will certainly sink current when not regulating.

collection the pack to the appropriate consistent current, and discharge the module come 0.1V, or as low as the load have the right to be controlled. Relying on the equipment, some modules deserve to be discharged to 0.1V and others to fifty percent of your initial voltage. Capacitance values will be slightly greater when the modules room discharged to half of your initial voltage fairly than 0.1V. Automatically remove the pack once the minimum voltage is reached, enabling the module"s voltage come bounce back. Measure the complying with parameters: Vw (initial functioning voltage) Vmin (minimum voltage under load) identifier (discharge current) Vf (voltage 5 seconds after removal of load) td (time to discharge from initial voltage to minimum voltage) calculation the capacitance follow to the following formula: Capacitance = (Id * td)/(Vw – Vf) (This change in voltage (Vw – Vf) is used because it eliminates the voltage drop as result of the equivalent collection resistance (ESR).) calculation the ESR follow to the adhering to formula: ESR = (Vf – Vmin)/Id (An LCR meter or bridge deserve to be provided to measure ESR at higher frequencies. The ESR at frequencies up to 100Hz will commonly be 50-60% of the DC ESR. The capacitance will be much lower, due to the structure of the electrode.)

Representative Measurement points for constant Current Test


Safety Considerations

As with all electrical testing, the investigator have to take appropriate precautions in the design and execution the the test. Proper precautions because that the voltage should be observed. Any type of interconnections must be sized for the maximum anticipated current and also insulated because that the suitable voltage. If repeated trial and error will be performed, cooling air might be forced to store the check module in ~ its operation temperature range.

What Is the Best way to dimension an Ultracapacitor for an Application?

The system variables needed are provided to calculate the dimension and variety of ultracapacitor cells ideal for any kind of application. In stimulate to get the most accurate evaluate of what is necessary, the adhering to parameters need to be defined:

Maximum charged voltage the the ultracapacitor cell or module (Vmax) functioning voltage that the ultracapacitor cabinet or module (Vw) Minimum voltage of the ultracapacitor cell or module (Vmin) Required existing (in amps) to discharge the ultracapacitor cabinet or module (I) expression (in seconds) that discharge from Vw to Vmin (td) full capacitance of the ultracapacitor cell or module (C) Equivalent collection resistance of the ultracapacitor cabinet or module (ESR)

These values deserve to be provided in some an easy exercises to determine the dimension and variety of ultracapacitor cells compelled for the application. The size and variety of cells forced depends top top the full ultracapacitor discharge-cycle voltage drop. During the discharge bike of an ultracapacitor, there space two voltage-drop parameters come consider: the voltage drop as result of equivalent series resistance (ESR) and the voltage drop due to capacitance.

Discharge Curve


As have the right to be watched above, during a discharge bicycle the early stage voltage autumn is because of the ultracapacitor’s ESR. The quantity of the autumn is a duty of the ESR and discharge present as shown by the following equation: dVESR= ns * ESR

After the initial voltage drop because of ESR, the capacitor will discharge follow to the capacitance and also discharge current, as suggested by the adhering to equation: dVcap= ns * td/C

By put these two equations together, the complete voltage drop can be calculated per the complying with equation: dVTotal = i * td/C + ns * ESR

The full voltage drop shows the number and size that the ultracapacitor cells forced to fulfill the demands of the application. Please keep in mind that enabling a bigger drop in voltage will reduce the important capacitance. Typically, by allowing the ultracapacitor cell or module come drop to fifty percent of the Vw value, 75% the the ultracapacitor’s energy will be discharged.

What are the Soldering and Handling references for Ultracapacitors?

Tecate team carries a range of different ultracapacitor cells. Most of these products are designed come be mounted to computer boards by method of soldering, and every one of them are RoHS-compliant and also thus have lead-free prepare that require adjustments in the processes supplied to interconnect them through their substrates.

Please note that the process and parameters defined here were occurred on particular equipment and also apply most totally to the equipment. It is very likely that different pieces of equipment will require fine-tuning the those parameters to accomplish optimal results.

General Precautions

There is a danger of the ultracapacitor cell deteriorating due to excessive warmth exposure during soldering, and there may likewise be a buildup of interior pressure. Depending on the form and size of the board, overheating the ultracapacitor cell may also cause the safety vent come burst. These outcomes will substantially shorten the life that the cells and also may reason leaking problems.

Be certain not to dip the whole of the ultracapacitor cabinet bodies right into melted solder and also to just flux the leads of the cells. Ensure the there is no direct contact between the sleeves of the ultracapacitor cells and also the pc board or any type of other component as excessive heat during soldering may cause sleeves to shrink or crack. Similarly, do not touch the sleeves with the soldering rod, as that can cause them to melt or crack.

Hand Soldering

In order to solder ultracapacitor cells by hand, an excellent soldering practices need to be used. The solderer should have experience through hand soldering of digital components and understand fundamental soldering processes. In general, lead-free soldering by hand requires higher heat and much more active fluxes 보다 solder comprise lead as a constituent. Therefore, brand-new thermal profiles need to be embraced and brand-new cleaning agents should be used.

The recommended temperature that the soldering rod pointer is no much more than 350°C. The soldering duration should be shorter than 3 seconds. Minimize the moment that the soldering iron is in direct call with the terminals of the ultracapacitor cells, as extreme heating the the leads may result in greater ESR.

Wave Soldering

In bespeak to tide solder components, distinct attention have to be paid to the dwell time and total time in ~ temperature, due to the fact that ultracapacitors room temperature-sensitive components. Preheat the plank from the bottom next only, happen the top of the board to 100°C, maximum, immediately before soldering. The preheat time will rely upon the heater efficiency, but use a preferably preheating time that 60 seconds.

The encourage conveyor rate is 2.8cm per second, and the soldering expression time need to be much shorter than 2.5 seconds. Minimize the moment that the soldering iron is in direct call with the terminals that the ultracapacitor, as excessive heating the the leads may an outcome in higher ESR.

Due to the fairly high thermal masses of the components, and also especially if the total number or thickness of the components is high, the use of a conventional thermo-profiling machine is strongly recommended to prevent excessively high temperatures.

Automated Soldering

Soldering may be automated v a hot-bar soldering jig, with soldering irons an installed on an automated raise-lower an equipment with time and also pressure controls. It is also possible to mount cells making use of conductive adhesive, ultrasonic welding, or laser welding.


Do not usage solvent cleaners, together these may damage the machine packaging; not correct solvents include acetone, benzene, isopropil alcohol, and halogenated solvents. Instead, use just aqueous clean solutions based upon deionized water.

Washing have to take ar at elevated temperatures no exceeding 70°C. Spray pressures need to not exceed 50psi.

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Post-wash drying need to be preserved to the minimum essential duration, at temperatures no exceeding 80°C. Fast airflow approximately the modules during drying will aid in the remove of humidity trapped in the packages.