US20090174972A1 - High-Power Ultracapacitor Energy Storage Pack and Method of Use - Google Patents
High-Power Ultracapacitor Energy Storage Pack and Method of Use Download PDFInfo
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- US20090174972A1 US20090174972A1 US12/359,648 US35964809A US2009174972A1 US 20090174972 A1 US20090174972 A1 US 20090174972A1 US 35964809 A US35964809 A US 35964809A US 2009174972 A1 US2009174972 A1 US 2009174972A1
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- ultracapacitor
- energy storage
- storage cell
- cell pack
- assembly
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/004—Details
- H01G9/008—Terminals
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L1/00—Supplying electric power to auxiliary equipment of vehicles
- B60L1/003—Supplying electric power to auxiliary equipment of vehicles to auxiliary motors, e.g. for pumps, compressors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
- B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
- B60L3/0046—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to electric energy storage systems, e.g. batteries or capacitors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
- B60L3/0023—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train
- B60L3/0069—Detecting, eliminating, remedying or compensating for drive train abnormalities, e.g. failures within the drive train relating to the isolation, e.g. ground fault or leak current
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L3/00—Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption
- B60L3/04—Cutting off the power supply under fault conditions
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L50/00—Electric propulsion with power supplied within the vehicle
- B60L50/40—Electric propulsion with power supplied within the vehicle using propulsion power supplied by capacitors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L50/00—Electric propulsion with power supplied within the vehicle
- B60L50/50—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells
- B60L50/60—Electric propulsion with power supplied within the vehicle using propulsion power supplied by batteries or fuel cells using power supplied by batteries
- B60L50/64—Constructional details of batteries specially adapted for electric vehicles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
- B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
- B60L58/18—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules
- B60L58/21—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries of two or more battery modules having the same nominal voltage
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L58/00—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles
- B60L58/10—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries
- B60L58/24—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries for controlling the temperature of batteries
- B60L58/26—Methods or circuit arrangements for monitoring or controlling batteries or fuel cells, specially adapted for electric vehicles for monitoring or controlling batteries for controlling the temperature of batteries by cooling
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G9/00—Electrolytic capacitors, rectifiers, detectors, switching devices, light-sensitive or temperature-sensitive devices; Processes of their manufacture
- H01G9/004—Details
- H01G9/08—Housing; Encapsulation
- H01G9/12—Vents or other means allowing expansion
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02H—EMERGENCY PROTECTIVE CIRCUIT ARRANGEMENTS
- H02H7/00—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions
- H02H7/16—Emergency protective circuit arrangements specially adapted for specific types of electric machines or apparatus or for sectionalised protection of cable or line systems, and effecting automatic switching in the event of an undesired change from normal working conditions for capacitors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L2240/00—Control parameters of input or output; Target parameters
- B60L2240/40—Drive Train control parameters
- B60L2240/54—Drive Train control parameters related to batteries
- B60L2240/545—Temperature
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
- B60L2240/00—Control parameters of input or output; Target parameters
- B60L2240/40—Drive Train control parameters
- B60L2240/54—Drive Train control parameters related to batteries
- B60L2240/547—Voltage
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- 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
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Sustainable Energy (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Charge And Discharge Circuits For Batteries Or The Like (AREA)
- Electric Double-Layer Capacitors Or The Like (AREA)
Abstract
An ultracapacitor energy storage cell pack includes an ultracapacitor assembly including a plurality of parallel ultracapacitors and balancing resistors in series; an enclosure for the ultracapacitor assembly; a controller; one or more temperature sensors; a pack voltage sensor; a GFI sensor; one or more cooling fans carried by the enclosure; an on/off relay coupled to the ultracapacitor assembly and the controller, the on/off relay activated by the controller during normal operation of the ultracapacitor assembly and deactivated by the controller when the GFI sensor detects a ground fault interrupt condition, the one or more temperature sensors detect an over-temperature condition, or the pack voltage sensor detects an over-voltage condition; and a pre-charge resistor and a pre-charge relay coupled to the ultracapacitor assembly and the controller, and activated by the controller to cause the pre-charge resistor to limit pack charge current until the ultracapacitor assembly reaches a minimum voltage.
Description
- This patent application is a continuation of U.S. patent application Ser. No. 11/460,738, filed Jul. 28, 2006, which is a continuation of U.S. patent application Ser. No. 10/720,916, filed Nov. 24, 2003, issued as U.S. Pat. No. 7,085,112 on Aug. 1, 2006, which is a continuation-in-part application of U.S. patent application Ser. No. 09/972,085, filed Oct. 4, 2001, issued as U.S. Pat. No. 6,714,391 on Mar. 30, 2004. These applications/patents are incorporated by reference herein as though set forth in full.
- The field of the invention relates to a high-voltage, high-power ultracapacitor energy storage pack composed of a large number of serially connected individual low-voltage ultracapacitor cells that store an electrical charge.
- The connecting together of individual battery cells for high-voltage, high-energy applications is well known. However, the chemical reaction that occurs internal to a battery during charging and discharging typically limits deep-cycle battery life to hundreds of charge/discharge cycles. This characteristic means that the battery pack has to be replaced at a high cost one or more times during the life of a hybrid-electric or all-electric vehicle. Batteries are somewhat power-limited because the chemical reaction therein limits the rate at which batteries can accept energy during charging and supply energy during discharging. In a hybrid-electric vehicle application, battery power limitations restrict the drive system efficiency in capturing braking energy through regeneration and supplying power for acceleration.
- Ultracapacitors are attractive because they can be connected together, similar to batteries, for high-voltage applications; have an extended life of hundreds of thousands of charge/discharge cycles; and can accept and supply much higher power than similar battery packs. Although ultracapacitors are typically more expensive than battery packs for the same applications and cannot store as much energy as battery packs, ultracapacitor packs are projected to last the life of the vehicle and offer better fuel-efficient operation through braking regeneration energy capture and supplying of vehicle acceleration power.
- During charging and discharging operation of the ultracapacitors, parasitic effects cause the cell temperature to increase. Cooling is required to minimize increased temperature operation that would degrade the energy storage and useful life of each ultracapacitor.
- Low-voltage energy cells, batteries, or ultracapacitors are connected in series to obtain high-voltage energy storage. Because of variations in materials and manufacturing, energy storage cells are not perfectly matched. As the serially connected pack operates through multiple charge and discharge cycles, the cell differences cause the energy storage to become more and more imbalanced among the cells. The energy storage imbalance from cell to cell limits the performance of the overall pack and can shorten the life of the individual cells.
- Packs of batteries and packs of ultracapacitors have been built in various forms and configurations. Various different wiring harnesses, buss bars, and connections have been used for current routing and voltage monitoring. Various different types of circuits for charging, discharging, and equalizing have also been built. Energy storage cells have been mounted in various “egg crate” or “wine rack” style vertical and horizontal support structures. High-voltage packages contain batteries enclosed within a single pack. Batteries have even been connected together by simply touching under some pressure the positive end of one battery against the negative end of another battery such as can be found in flashlights, small toys and appliances. High-energy packs usually include some form of convection air or liquid cooling.
- The present invention involves an ultracapacitor high-energy storage pack with structural support, environmental protection, automatic cooling, electrical interconnection of the ultracapacitors, remote ON/OFF switching, a safety pre-charge circuit, a safety and automatic equalizing discharge circuit, a programmable logic controller, a digital interface to a control area data network for control and status reporting, and an optional fire sensing and suppression system. The pack is ideal for high-voltage, high-power applications of electric and hybrid-electric vehicle propulsion systems, fixed site high-power load averaging, and high-power impulse requirements. The pack is housed in an aluminum box enclosure with a detachable access lid. The inside of the box has a thick anti corrosion, electrically insulating coating. The box has holes cut out for the mounting of cooling fans, air intakes, and electrical connections. The air intake cutouts have provision for mounting external replaceable air filters that can be serviced without opening the box. Mounted to the interior of the box are aluminum guide support strips for three plastic support plates. Plastic, as a non-conductive material, provides for the safe operation of the high-voltage connections. Two of the plastic plates have wine rack hole cutouts that form the support structure for individual cylindrical ultracapacitor cans and the third plastic plate has pre mounted buss bars and smaller holes for fastening bolts. The first two plastic plates structurally support and separate the ultracapacitors to provide space for cooling airflow along the direction of the plates. The third plate supports and positions the cans by the threaded end terminals that are bolted to the plate. Buss bars are fastened to the inside of the third plate to provide connections between adjacent rows of ultracapacitors. The cans, which are arranged in rows of three, are electrically and structurally connected together with threaded studs and buss bars.
- In a preferred embodiment, the triple can connections are arranged four rows deep and twelve rows along the top to efficiently package one-hundred and forty four (144) cylindrically shaped ultracapacitor cans with threaded polarized connections at each end of the can. For different design requirements, the longitudinal dimension of the box may be shortened or lengthened to respectively delete or add one or more layers of twelve (12) ultracapacitors. Similarly, the depth dimension of the box may be shortened or lengthened to respectively delete or add a layer of thirty-six (36) ultracapacitors. Again similarly, the width dimension of the box may be shortened or lengthened to respectively delete or add a layer of forty-eight (48) ultracapacitors.
- In addition to the ultracapacitors, the box houses and has mounting provision for other electrical components. Temperature sensors and controllers switch the forced-air cooling fans on and off for thermal management of the ultracapacitor environment. A pre-charge resistor is automatically switched in series with the power charge circuit when first turned on to prevent overloading the charging energy source. High-power relays called contactors provide remote controlled switching of the energy storage pack into and out of the charge and load circuits. An integral Control Area Network (CAN) controller is connected to multiple pin electronics connectors to report status parameters and control the switching of the energy storage pack through a CAN digital data network. The pack also contains integral Ground Fault Interrupter (GFI) and fire sensing automatic safety shutoff systems.
- Finally, a balancing or drain resistor is mounted in parallel around each ultracapacitor to safely discharge the pack to an inactive state over a period of time. This periodic discharge function also serves to equalize all the ultracapacitors energy storage to a balanced condition.
- A further aspect of the invention involves an ultracapacitor energy storage cell pack including an ultracapacitor assembly having a plurality of parallel ultracapacitors and balancing resistors in series, each balancing resistor in parallel with each ultracapacitor to automatically discharge each ultracapacitor over time, thereby balancing the ultracapacitors of the ultracapacitor assembly; an enclosure to enclose and protect the ultracapacitor assembly; a controller for the ultracapacitor assembly; one or more temperature sensors to monitor temperature of the ultracapacitor assembly and coupled to the controller; a pack voltage sensor to monitor voltage of the ultracapacitor assembly and coupled to the controller; a GFI sensor to monitor for a ground fault interrupt condition of the ultracapacitor assembly and coupled to the controller; one or more cooling fans carried by the enclosure and controlled by the controller to cool the ultracapacitor assembly based upon temperature sensed by the one or more temperature sensors; an on/off relay coupled to the ultracapacitor assembly and the controller, the on/off relay activated by the controller during normal operation of the ultracapacitor assembly and deactivated by the controller when the GFI sensor detects a ground fault interrupt condition, when the one or more temperature sensors detect an over-temperature condition, or when the pack voltage sensor detects an over-voltage condition; and a pre-charge resistor and a pre-charge relay coupled to the ultracapacitor assembly and the controller, the pre-charge relay activated by the controller to cause the pre-charge resistor to limit pack charge current until the ultracapacitor assembly reaches a minimum voltage.
- Another aspect of the invention involves a method of using an ultracapacitor energy storage cell pack including the steps of providing an ultracapacitor energy storage cell pack including a ultracapacitor assembly having a plurality of parallel ultracapacitors and balancing resistor in series, each balancing resistor in parallel with each ultracapacitor to automatically discharge each ultracapacitor over time, thereby balancing the ultracapacitors of the ultracapacitor assembly and assuring a safe condition for service personnel; an enclosure to enclose and protect the ultracapacitor assembly; a controller for the ultracapacitor assembly; one or more temperature sensors to monitor temperature of the ultracapacitor assembly and coupled to the controller; a pack voltage sensor to monitor voltage of the ultracapacitor assembly and coupled to the controller; a GFI sensor to monitor for a ground fault interrupt condition of the ultracapacitor assembly and coupled to the controller; one or more cooling fans carried by the enclosure and controlled by the controller to cool the ultracapacitor assembly based upon temperature sensed by the one or more temperature sensors; an on/off relay coupled to the ultracapacitor assembly and the controller, the on/off relay activated by the controller during normal operation of the ultracapacitor assembly and deactivated by the controller when the GFI sensor detects a ground fault interrupt condition, when the one or more temperature sensors detect an over-temperature condition, or when the pack voltage sensor detects an over-voltage condition; and a pre-charge resistor and a pre-charge relay coupled to the ultracapacitor assembly and the controller, the pre-charge relay activated by the controller to cause the pre-charge resistor to limit pack charge current until the ultracapacitor assembly reaches a minimum voltage; automatically discharging the ultracapacitors of the ultracapacitor energy storage cell with the balancing resistors to balance ultracapacitors of the ultracapacitor assembly and assure a safe condition for service personnel; cooling the ultracapacitor assembly with the one or more cooling fans based upon temperature sensed by the one or more temperature sensors; activating the on/off relay with the controller during normal operation of the ultracapacitor assembly and deactivating the on/off relay with the controller when the GFI sensor detects a ground fault interrupt condition, when the one or more temperature sensors detect an over-temperature condition, or when the pack voltage sensor detects an over-voltage condition; and activating the pre-charge relay with the controller to cause the pre-charge resistor to limit pack charge current until the ultracapacitor assembly reaches a minimum voltage.
- The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and together with the description, serve to explain the principles of this invention.
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FIG. 1 is an exploded perspective view drawing of an embodiment of a half module of an ultracapacitor energy storage cell pack. -
FIG. 2 is a perspective view of an embodiment of an ultracapacitor energy storage cell pack. -
FIG. 3 is a top plan view of an embodiment of a circuit board for the half module illustrated inFIG. 1 and ultracapacitor energy storage cell pack illustrated inFIG. 2 . -
FIG. 4 is an exploded perspective view of an alternative embodiment of a ultracapacitor energy storage cell pack. -
FIG. 5 is an exploded perspective view of the ultracapacitors and support plates of the ultracapacitor energy storage cell pack ofFIG. 4 . -
FIG. 6 is perspective detail view taken of detail 6 of the ultracapacitors, threaded interconnections between the ultracapacitors, and parallel drain resistors mounted with ring terminals of the ultracapacitor energy storage cell pack ofFIG. 5 . -
FIG. 7 is a side-elevational view of an embodiment of a middle support plate of the ultracapacitor energy storage cell pack illustrated inFIG. 4 , and the middle support plate is shown with cutouts for the ultracapacitors and the drain resistors. -
FIG. 8 is a side-elevational view of an embodiment of an end support plate of the ultracapacitor energy storage cell pack illustrated inFIG. 4 , and the end support plate is shown with cutouts for the mounting bolts and the support guide mounting rivets. -
FIG. 9 is a block diagram of the ultracapacitor energy storage cell pack illustrated inFIG. 4 . - With reference to
FIGS. 1 and 2 , an embodiment of an ultracapacitor energystorage cell pack 10 will now be described.FIG. 1 illustrates an exploded view of an embodiment of ahalf module 15 of the ultracapacitor energystorage cell pack 10.FIG. 2 illustrates an embodiment of an assembled ultracapacitor energy storagecell pack module 10, which includes twohalf modules 15 fastened together. Although eachhalf module 15 preferably includes eightyultracapacitors 20, each half module may have other numbers ofultracapacitors 20. Further, theultracapacitor pack 10 may have other numbers ofmodules 15 besides a pair (e.g., 1, 3, 4, etc.). - The
ultracapacitor pack 10 is shown in exploded view inFIG. 1 to illustrate the different levels in thehalf module 15 that are added during assembly of thehalf module 15. Each of these levels will now be described in turn below followed by a description of the assembly process. - An
aluminum base plate 25 forms a bottom or inner-most level of thehalf module 15. Thebase plate 25 includes a weldedframe 30 around edges of thebase plate 25. - A
polycarbonate crate plate 35 is seated inside theframe 30 and includes cutouts orholes 40 with a shape that matches the cross-section of theultracapacitors 20. Thebase plate 25 andcrate cutouts 40 form an x, y, and z location and mounting support for theultracapacitors 20. Thecutouts 40 also prevent theultracapacitors 20 from rotating during use, e.g., mobile vehicle use. - In the embodiment shown, the
individual ultracapacitors 20 have a general square-can shape (i.e., rectangular parallelpiped). The cross-section of theultracapacitors 20 is 2.38 in. by 2.38 in. and the length is about 6 in. On an upper-most or outer-most end of theultracapacitor 20, two threadedlug terminals 45 and a dielectric paste fillport 50 protrude from aninsulated cover 55 of theultracapacitor 20. Thecover 55 of the ultracapacitor may include a well encircled by a protruding rim. Shrink plastic that normally surrounds sides orexterior capacitor casing 60 of theultracapacitor 20 is removed to better expose theexterior casing 60 to circulated cooling air. The shrink plastic may be left on the bottom of theultracapacitor 20. - A
box frame 65 ties together thebase plate 25 andframe 30 withcircuit boards 70, and atop polycarbonate cover 75. Thebox frame 65 has elongatedlateral cutouts 80 on two opposing sides to provide for cross-flow air cooling.Bottom flanges 85 provide a mounting surface to tie two of these box frames 65, and, hence, twohalf modules 15, together to form the singleultracapacitor pack module 10 shown inFIG. 2 . Thebox frame 65 includes a large upper rectangular opening and a large lower rectangular opening. - The next layer is a first ¼-in. foam rubber insulating and sealing
sheet 90 that covers theultracapacitors 20. Thefirst sheet 90 has cutouts for theultracapacitor terminals 45 and fillport 50 so that thesheet 90 can seal tightly against thecover 55 of theultracapacitor 20. - A second ⅛-in. foam rubber insulating and sealing
sheet 95 may be placed on top of the previousfirst sheet 90. Thesecond sheet 95 includes rectangular cutouts or holes 100. Thecutouts 100 receive copper barelectrical interconnections 105. Thecutouts 100 in thesheet 95 simplify the assembly and proper placement of the copper barelectrical interconnections 105. Thesheet 95 also seals the copper barelectrical interconnections 105. The copper barelectrical interconnections 105 include holes that theultracapacitor terminals 45 protrude through. - Two identical main circuit boards 70 (e.g., 40-ultracapacitor main circuit boards) may lay on top of the
foam rubber sheets FIG. 3 , eachmain circuit board 70 may includeholes 107 that theultracapacitor terminals 45 protrude through. In the embodiment shown, eachcircuit board 70 may have mountingholes 107 for 40 (8 by 5) ultracapacitors less two corner positions required for frame structure mounting. Instead of twocircuit boards 70, asingle circuit board 70 may be used. Thus, as used herein, the word “circuit board” means one or more circuit boards. Fasteners such as lug nuts fasten theindividual ultracapacitor terminals 45 andcopper bars 105 to thecircuit boards 70 and compress thefoam rubber sheets cover 55 of theultracapacitor 20 and thecircuit boards 70. Thus, thecircuit board 70 forms the location and mechanical support as well as the electrical connections for theultracapacitors 20. Thefoam sheets ultracapacitor terminals 45. A processor and display circuit board mounts on top of themain circuit board 70. - Although the
ultracapacitor pack 10 and thehalf modules 15 are shown as being generally rectangular in shape, either or both may have shapes other than generally rectangular such as, but not by way of limitation, circular, oval, other curvilinear shapes, other rectilinear shapes, and other polygonal shapes. - A
top aluminum frame 110 and thetransparent polycarbonate cover 75 may attach to the frame structure to complete thehalf module 15. Thetransparent cover 75 allows observation of a light emitting diode (LED) failure detection display that indicates the active/inactive status of theultracapacitors 20. - Together, the
bottom base plate 25,crate plate 35,box frame 65, sealingsheets ultracapacitor mounting assembly 112 for theultracapacitors 20. Theultracapacitor mounting assembly 112 provides a mounting surface for the copper bar interconnects 105, maintains the position and spacing of theultracapacitors 20 in the X, Y, and Z directions, does not allow the ultracapacitors to rotate when connected, and the main circuit board(s) 70 provides a mounting platform for the cell equalization, failure detection, processor, and LED display systems. Attaching theultracapacitors 20 to the mountingassembly 112 by theterminals 45 instead of theexterior ultracapacitor casing 60 allows theultracapacitors 20 to be more effectively cooled because the majority of the surface area of theultracapacitors 20 is in the cooling air stream supplied by the cross-flowair cooling assembly 115. Sealing along thecover 55 and around theterminals 45 protects theterminals 45 from water, dust, and other contaminants. - An exemplary method of assembling the
ultracapacitor half module 15 will now be described. Theultracapacitors 20 are first placed onto thebottom base plate 25, with the bottoms of theultracapacitors 20 extending through thesquare cutouts 40 of thecrate plate 35. Thebox frame 65 is applied over theultracapacitors 20, so that the ultracapacitors extend through the large lower and upper rectangular openings of thebox frame 65. The ¼-in. foam rubber insulating and sealingsheet 90 is placed on top of theultracapacitors 20, with theultracapacitor terminals 45 and fillport 50 protruding through cutouts in thesheet 90. The ⅛-in. foam rubber insulating and sealingsheet 95 is placed on top of theprevious sheet 90 and the copper barelectrical interconnections 105 are placed into therectangular cutouts 100 of thesheet 95. Theultracapacitor terminals 45 also protrude through holes in the copper barelectrical interconnections 105. Themain circuit boards 70 are layered on top of thefoam rubber sheets ultracapacitor terminals 45 protrude through the corresponding holes in thecircuit boards 70. Lug nuts are screwed onto the threadedterminals 45, compressing thefoam rubber sheets cover 55 of theultracapacitor 20 and thecircuit boards 70, and securing theultracapacitors 20 andcopper bars 105 in position. The processor and display circuit board is mounted on top of themain circuit board 70. Thetop aluminum frame 110 and thetransparent polycarbonate cover 75 are placed over the circuit boards and attached to the frame structure to complete thehalf module 15. A pair ofhalf modules 15 may be positioned back to back (i.e., facing opposite directions with the bottoms of thealuminum base plates 25 touching) and a cross-flowair cooling assembly 115 may be attached to the frame structure, adjacent the elongatedlateral cutouts 80 on one side of the box frames 65. Thehalf modules 15 may be bolted or otherwise fastened together at the respectivebottom flanges 85 to complete theultracapacitor pack module 10. - To determine if one or
more ultracapacitors 20 in thepack 10 need to be replaced, a user observes the light emitting diode (LED) failure detection display through thetransparent cover 75. The LED failure detection display includes an array of LEDs that correspond to the array ofultracapacitors 20, each LED indicating the status of acorresponding ultracapacitor 20. Each unlit LED indicates a corresponding failed LED. An ultracapacitor 20 in thepack 10 can quickly and easily be replaced by simply unfastening the frame and unbolting only the failedultracapacitor 20 that had been previously identified by the LED display. The replacement ultracapacitor is put into position and the procedure reversed. - With reference to
FIGS. 4-9 , and initially,FIGS. 4 and 5 , an ultracapacitor energy storage cell pack (hereinafter “ultracapacitor pack) 200 constructed in accordance with another embodiment of the invention will now be described. Theultracapacitor pack 200 includes a ultracapacitor cell and winerack support assembly (hereinafter “ultracapacitor assembly”) 210, an ultracapacitor pack box enclosure (hereinafter “box enclosure”) 220, ametal lid 230, an air filter bracket 240 (w/air filter), coolingfans 250, fan finger guards 260, higher-power precharge resistor 270, Programmable Logic Controller module (hereinafter “PLC”) 280, high power relays (kilovac contactors) 290,electrical connectors box enclosure 220. - The
ultracapacitor assembly 210 includes one-hundred and forty-four (144)ultracapacitors 330 connected in series to provide a nominal 360 volts DC, 325 watt-hours energy storage. The value of each ultracapacitor 330 is 2600 Farads. In alternative embodiments, theultracapacitor assembly 210 may have other numbers of ultracapacitors, different types of ultracapacitors, and/or an overall different amount of voltage and/or power. Eachultracapacitor 330 is connected with a parallel drain resistor 340 (FIG. 6 ). Theultracapacitor assembly 210 includes a first wine rackmiddle support plate 350, a similar second wine rackmiddle support plate 360, and a wine rackend support plate 370 for supporting theultracapacitors 330. - The
box enclosure 220 is preferably made of metal and includessquare end cutouts 380 inrear wall 382 to accommodate air flow therethrough andcircular cutouts 390 infront wall 392 to accommodate the coolingfans 250. Thefront wall 392 andrear wall 382 are joined by oppositeparallel side walls 394. The filter(s) of theair filter bracket 240 is externally serviceable and fits over thesquare cutouts 380 of therear wall 382. The interior of thebox enclosure 220 and underside of thelid 230 is coated with a thick material that provides electrical insulation and corrosion protection as an additional level of safety for thebox enclosure 220. The inner bottom of thebox enclosure 220 includes support plate guides for mounting the wine rackmiddle support plates support plate 370. -
FIG. 5 shows an exploded view of theultracapacitor assembly 210. Theultracapacitors 330 are cylindrical canisters with aluminum female threaded connections at each end, which receive male threadedaluminum interconnection studs 400 for connecting theultracapacitors 330 in series. Aluminum bus bars 410 and aluminum interconnection washers are also used to interconnect theultracapacitors 330 in series at the ends of the rows. Providing electrical connections made of aluminum metal prevents any corrosive galvanic effects from dissimilar metals. Additionally, the threaded connections are covered with a silicon dielectric grease to prohibit environmentally caused corrosion. - The wine rack
middle support plates support plate 370 are made of nonconductive plastic material to prevent any high-voltage arcing or other high-voltage leakage effects that could occur over time due to vibration and shock. The wine rackmiddle support plates support plate 370 are different in construction to allow ease of assembly and replacement of any canister row. - With reference to
FIG. 7 , the wine rackmiddle support plates circular cutouts 430 for receiving theultracapacitors 330. Thecutouts 430 include an additionalsemi-circular recess 440 to accommodate and support thedrain resistors 340. Thedrain resistors 340 are preformed with ring terminals 442 (FIG. 6 ) attached to leads of thedrain resistors 340 for simplicity of mounting and electrical connection. Additional semi-circular recesses 450 along atop edge 460 andbottom edge 470 of the wine rackmiddle support plates box enclosure 220 and thelid 230. The wine rackmiddle support plates - With reference to
FIG. 8 , the wine rackend support plate 370 includes a pattern ofcircular holes 480 for receiving threaded bolt fasteners for mounting theultracapacitors 330. Additionalsemi-circular recesses 490 along atop edge 500 and a bottom edge 510 of the wine rackend support plate 370 provide clearance for the attaching rivets of support guides on a bottom of thebox enclosure 220 and thelid 230. The wine rackend support plate 370 is made of 3/16″ thick Grade G-10/FR4 Garolite glass fabric laminate with an epoxy resin that absorbs virtually no water and holds its shape well. Inside-mounted aluminum bus bars 410 are affixed in place to the wine rackend support plate 370 with silicon RTV (Room Temperature Vulcanizing, which is a common jelly-like paste that cures to a rubbery substance used in various applications as adhesive and/or sealer). The bus bars 410 are pre-positioned to avoid confusion that could cause assembly mistakes. -
FIG. 9 is a general block diagram of theultracapacitor pack 200. As indicated above, eachultracapacitor 330 is connected in parallel with thedrain resistor 340. One-hundred and forty-four (144) of these parallel connections are connected in series to provide a nominal 360 volts DC, 325 watt-hours energy storage. The value of each ultracapacitor 330 is 2600 Farads and the value and power of thedrain resistor 340 is selected to completely discharge theultracapacitor 330 over a number of hours during an inactive period of theultracapacitor pack 200. The energy drain action is slow enough so as not to interfere with the normal operation of theultracapacitor pack 200. The discharge is also slow enough so as not to cause any significant temperature increase from thedrain resistors 340 within theultracapacitor pack 200. The chemical composition of theultracapacitor 330 allows charge to build up across theultracapacitor 330 over a period of time after theultracapacitor 330 is shorted and left open. Thedrain resistors 340 allow a safe discharge of the high voltage of theultracapacitor pack 200 to eliminate any shock danger from the ultracapacitor “memory” to personnel servicing theultracapacitor pack 200. - Because the
ultracapacitors 330 can accept hundreds of amperes of electrical current during charging, a connection to an energy source would appear as a short circuit to the energy source. To accommodate this problem, a high-power pre-charge resistor 270 with its own heat sink is mounted inside thebox enclosure 220 and used to limit the initial charging current. Based on input to apack voltage sensor 520, thePLC 280 controls apre-charge contactor relay 540 to engage thepre-charge resistor 270 until theultracapacitors 330 reach a minimum safe voltage level. - The
PLC 280 is the control center for additional features. Through a Control Area Network (CAN) bus interface (e.g., SAE standard J1939), thePLC 280 offers remote ON/OFF control and status reporting of: the control relay positions for on/offrelay 550 andprecharge relay 540,pack voltage sensor 520, ground fault interrupt (GFI)sensor 560, coolingfans 250,box temperature sensor 570, overtemperature sensor 580,optional fire sensor 590, and optionalfire suppression system 600. ThePLC 280 also uses input from thebox temperature sensor 570 to turn on and off the coolingfans 250. During normal operation of the ultracapacitor pack, the on/offrelay 550 is activated. The on/offrelay 550 is deactivated by thePLC 280 when theGFI sensor 560 detects a ground fault interrupt condition, when the overtemperature sensor 580 detects an over-temperature condition, or thepack voltage sensor 520 detects an over-voltage condition. Thefire suppression system 600 is activated by thePLC 280 in the event a fire condition is detected by thefire sensor 590 to extinguish any fire in theultracapacitor pack 200. A 360 VDC+ stud feed thru 610 is an external power cable attachment for the positive side of theultracapacitor pack 200. A 360 VDC− stud feed thru 620 is an external power cable attachment for the negative side of theultracapacitor pack 200. A 24 VDC+, 24 VDC−power connector 630 provides the positive and negative dc power connections for thePLC 280. A digitaldata interface connector 640 includes the wires that connect to the CAN buss network and is also the port by which thePLC 280 is programmed. - The
ultracapacitor pack 200 includes structural support, environmental protection, automatic cooling, electrical interconnection of the ultracapacitors, remote ON/OFF switching, a safety pre-charge circuit, a safety and automatic equalizing discharge circuit, a programmable logic controller, a digital interface to a control area data network for control and status reporting, and an optional fire sensing and suppression system. The pack is ideal for high-voltage, high-power applications of electric and hybrid-electric vehicle propulsion systems, fixed site high-power load averaging, and high-power impulse requirements. - While embodiments and applications of this invention have been shown and described, it would be apparent to those in the field that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims.
Claims (20)
1. An ultracapacitor energy storage pack specially adapted for a hybrid electric vehicle, the ultracapacitor energy storage pack comprising:
an ultracapacitor assembly including a plurality of parallel ultracapacitors and balancing resistors in series, each balancing resistor in parallel with each ultracapacitor and configured to automatically discharge each ultracapacitor over time, thereby balancing the ultracapacitors of the ultracapacitor assembly;
an enclosure configured to enclose and protect the ultracapacitor assembly;
a pack voltage sensor configured to monitor voltage of the ultracapacitor assembly;
one or more temperature sensors configured to monitor temperature of the ultracapacitor assembly;
a ground fault sensor configured to monitor for a ground fault condition between the ultracapacitor assembly and the hybrid electric vehicle;
an on/off relay coupled to the ultracapacitor assembly and an on/off relay control input, the on/off relay activated during normal operation of the ultracapacitor assembly and deactivated by the on/off relay control input to terminate normal operation of the ultracapacitor assembly; and,
a cooling system configured to cool the ultracapacitor assembly.
2. The ultracapacitor energy storage cell pack of claim 1 , wherein the ultracapacitor energy storage cell pack is configured to capture braking regeneration energy of the hybrid electric vehicle.
3. The ultracapacitor energy storage cell pack of claim 2 , wherein the ultracapacitor energy storage cell pack is further configured to supply vehicle acceleration power to the hybrid electric vehicle.
4. The ultracapacitor energy storage cell pack of claim 1 , wherein the cooling system comprises one or more cooling fans carried by the enclosure.
5. The ultracapacitor energy storage cell pack of claim 4 , further comprising an air filter carried by the enclosure, the air filter configured to filter cooling air entering the enclosure.
6. The ultracapacitor energy storage cell pack of claim 5 , wherein the air filter and the one or more cooling fans are positioned on opposite sides of the enclosure; and,
wherein the air filter interfaces with one or more cutouts in the enclosure; and,
wherein the one or more cooling fans are configured to force air from the enclosure that is drawn in through the air filter.
7. The ultracapacitor energy storage cell pack of claim 1 , further comprising a controller.
8. The ultracapacitor energy storage cell pack of claim 7 , wherein the controller is coupled to cooling system and is configured to provide automatic cooling of the ultracapacitor assembly in response to the one or more temperature sensors.
9. The ultracapacitor energy storage cell pack of claim 8 , wherein the cooling system comprises one or more cooling fans coupled to the enclosure; and,
wherein the controller is further configured to turn the one or more cooling fans on and off in response to the one or more temperature sensors.
10. The ultracapacitor energy storage cell pack of claim 7 , further comprising a pre-charge resistor and a pre-charge relay coupled to the on/off relay, to the ultracapacitor assembly, and to the controller, the pre-charge relay activated by the controller to cause the pre-charge resistor to limit electrical current entering the ultracapacitor energy storage cell pack until the ultracapacitor assembly reaches a minimum voltage, or to limit electrical current leaving the ultracapacitor energy storage cell pack until an external load circuit reaches a minimum voltage.
11. The ultracapacitor energy storage cell pack of claim 7 , wherein the controller is coupled to at least one of the voltage sensor, the one or more temperature sensors, the ground fault sensor, the on/off relay, a fire sensor, and a fire suppression subassembly.
12. The ultracapacitor energy storage cell pack of claim 11 , wherein the controller is configured to control one or more of the on/off relay and the fire suppression subassembly in response to at least one of the voltage sensor, the one or more temperature sensors, the ground fault sensor, the on/off relay, and the fire sensor.
13. The ultracapacitor energy storage cell pack of claim 7 , wherein the controller comprises a programmable logic controller module.
14. The ultracapacitor energy storage cell pack of claim 13 , wherein the hybrid electric vehicle includes a vehicle communications bus, the ultracapacitor energy storage cell pack further comprising a digital data interface to the vehicle communications bus; and,
wherein the programmable logic controller module is coupled to the digital data interface and is configured to be programmed across the vehicle communications bus via the digital data interface.
15. The ultracapacitor energy storage cell pack of claim 14 , wherein the controller monitors and reports sensor inputs across the vehicle communications bus via the digital data interface, and controls the cooling system and on/off relay in response to commands from the vehicle communications bus received via the digital data interface.
16. The ultracapacitor energy storage cell pack of claim 15 , wherein the digital data interface and the vehicle communications bus are compliant with an SAE standard J1939 Control Area Network (CAN).
17. The ultracapacitor energy storage cell pack of claim 1 , wherein the ultracapacitor energy storage cell pack stores at least a nominal 325 watt-hours of electrical energy at a nominal 360 volts DC.
18. The ultracapacitor energy storage cell pack of claim 1 , wherein the enclosure includes an inside surface with an anti-corrosion and electrical insulation coating thereon.
19. The ultracapacitor energy storage cell pack of claim 1 , wherein the ultracapacitor assembly includes two polycarbonate middle plate supports with cutouts that receive the plurality of parallel ultracapacitors and balancing resistors.
20. The ultracapacitor energy storage cell pack of claim 1 , wherein the ultracapacitor assembly includes an end support plate made of a glass fabric laminate with an epoxy resin, and has a pattern of holes for mounting the ultracapacitors.
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US12/359,648 US20090174972A1 (en) | 2001-10-04 | 2009-01-26 | High-Power Ultracapacitor Energy Storage Pack and Method of Use |
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Also Published As
Publication number | Publication date |
---|---|
US7630181B2 (en) | 2009-12-08 |
US7085112B2 (en) | 2006-08-01 |
US20060262467A1 (en) | 2006-11-23 |
US20040150926A1 (en) | 2004-08-05 |
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