U.S. patent application number 11/196864 was filed with the patent office on 2005-12-08 for common pole capacitor and housing apparatus and method.
Invention is credited to Gallay, Roland, Schlunke, Daniel.
Application Number | 20050268445 11/196864 |
Document ID | / |
Family ID | 35005158 |
Filed Date | 2005-12-08 |
United States Patent
Application |
20050268445 |
Kind Code |
A1 |
Gallay, Roland ; et
al. |
December 8, 2005 |
Common pole capacitor and housing apparatus and method
Abstract
A housing is provided for connecting two capacitor cells in a
series or parallel combination and for providing the two cells as
one integral product.
Inventors: |
Gallay, Roland;
(Farvagny-le-Petit, CH) ; Schlunke, Daniel;
(Chatonnaye, CH) |
Correspondence
Address: |
Gregory J. Koerner
Redwood Patent Law
1291 East Hillsdale Boulevard
Suite 205
Foster City
CA
94404
US
|
Family ID: |
35005158 |
Appl. No.: |
11/196864 |
Filed: |
August 4, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11196864 |
Aug 4, 2005 |
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10889205 |
Jul 12, 2004 |
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6952338 |
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60518421 |
Nov 7, 2003 |
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Current U.S.
Class: |
29/25.41 ;
361/502 |
Current CPC
Class: |
H01G 9/155 20130101;
H01G 9/08 20130101; Y02E 60/13 20130101; Y10T 29/43 20150115; H01G
9/14 20130101 |
Class at
Publication: |
029/025.41 ;
361/502 |
International
Class: |
H01G 007/00 |
Claims
What is claimed is:
1. A method of manufacturing a capacitor, comprising the steps of:
providing a first and a second jellyroll capacitor cell; providing
a capacitor housing; inserting the first jellyroll capacitor cell
into the housing; and inserting the second jellyroll capacitor cell
into the capacitor housing.
2. The method of claim 1, further comprising the step of
electrically attaching the first and second capacitor together.
3. The method of claim 2, wherein the step of electrically
attaching comprises attaching the first and second capacitor cell
to a sealing portion.
4. The method of claim 3, wherein the sealing portion is disposed
within the housing.
5. The method of claim 1, further comprising the step of sealing
the housing.
6. The method of claim 1, wherein the capacitor cells comprise
double-layer capacitors.
7. The method of claim 1, wherein the housing comprises a double
open-ended housing.
8. The method of claim 1, wherein the first and second jellyroll
capacitor cell are connected together in one connection step.
9. A method of manufacturing a capacitor, comprising the steps of:
providing a first and a second jellyroll capacitor cell; providing
a housing; and connecting the first jellyroll capacitor cell and
the second jellyroll capacitor cell to the housing in one
connecting step.
10. The method of claim 9, wherein the coupling step comprises a
welding step.
11. The method of claim 9, wherein the coupling step comprises a
soldering step.
12. The method of claim 9, wherein the coupling step comprises a
brazing step.
13. The method of claim 9, wherein the coupling step comprises a
gluing step.
14. The method of claim 9, wherein the one connecting step
comprises connecting to a conductive separator disposed within the
housing.
15. A method of manufacturing a capacitor, comprising the steps of:
providing a first and a second jellyroll capacitor cell; providing
a capacitor housing; coupling the first jellyroll capacitor cell to
the second jellyroll capacitor cell; inserting the first jellyroll
capacitor cell and the second jellyroll capacitor cell into the
housing.
16. The method of claim 15, wherein the two jellyrolled capacitors
cells are coupled to a conductive separator.
Description
RELATED APPLICATIONS
[0001] This Application is related to and claims priority from
commonly assigned U.S. Provisional Application 60/518,421, filed 7
Nov. 2003, DKT. # M107P, and from commonly-assigned U.S.
Non-Provisional application Ser. No. 10/889,205, filed 12 Jul.,
2005, DKT. # M107US.
BACKGROUND
[0002] High capacity double-layer capacitor cells (also known as
super-capacitors and ultra-capacitors) are rated for operation at
low voltages. The operating cell voltages of double-layer capacitor
cells are typically no more than about 4 volts and nominally about
2.7 volts. Charge storage devices are often used in combination to
provide higher energy delivery and/or higher capacitance. To
provide such higher energy delivery and/or higher capacitance, one
or more interconnection typically needs to be made. It would be
desirable that such interconnections be as simple and reliable as
possible.
SUMMARY
[0003] In one embodiment, an energy storage device packaging system
comprises a housing, the housing having a body and a separator, the
body having a first opening and a second opening, the separator
disposed within the housing, and the first and second opening
separated by the separator; a first energy storage device cell,
disposed within the body and coupled to a first side of the
separator; and a second energy storage device cell disposed within
the body and coupled to a second side of the separator. In one
embodiment, the first cell and the second cell are double-layer
capacitors. In one embodiment, the first cell and the second cell
each have a maximum operating voltage of about 4 volts. In one
embodiment, the housing comprises a battery sized form factor. In
one embodiment, the separator is in conductive contact with the
housing. In one embodiment, the first and second cell are connected
in series. In one embodiment, the first and second cell are
connected in parallel. In one embodiment, the cells and the housing
are coupled to a balancing circuit.
[0004] In one embodiment, a double-layer capacitor product
comprises a housing, the housing having a body and a separator, the
body having a first opening and a second opening, the separator
disposed within the housing, and the first and second opening
separated by the separator; a first double-layer capacitor cell,
disposed within the body and coupled to a first side of the
separator; and a second double-layer capacitor cell disposed within
the body and coupled to a second side of the separator. In one
embodiment, the product is rated to operate above 4 volts. In one
embodiment, the housing and the separator are in conductive
contact.
[0005] In one embodiment, a capacitor product comprises a first
jellyroll type capacitor cell, the cell comprising at least one
collector; and a second jellyroll type capacitor cell, cell
comprising at least one collector, wherein the at least one
collector of the first cell is electrically coupled to the at least
one collector of the second cell by a welded connection.
[0006] In one embodiment, a method of manufacturing a capacitor
comprise the steps of: providing a first and a second capacitor
cell; providing a capacitor housing; inserting the first capacitor
cell into the housing; and inserting the second capacitor into the
capacitor housing. The method may further include a step of
electrically attaching the first and second capacitor together. The
step of electrically attaching may comprise attaching the first and
second capacitor to a sealing portion. The sealing portion may be
disposed within the housing. The capacitors may comprise
double-layer capacitors. The housing may comprise a double
open-ended housing. The housing may comprise a battery sized form
factor. The first and second cell may each comprise a jellyroll
type structure, wherein the two jellyroll structures are connected
together in one connection step.
[0007] In one embodiment, a method of manufacturing a capacitor may
comprise the steps of: providing a first and a second capacitor
cell; providing a housing; and connecting the first capacitor cell
and the second capacitor cell to the housing in one connecting
step. The coupling step may comprise a welding step. The coupling
step may comprise a soldering step. The coupling step may comprise
a brazing step. The coupling step may comprise a gluing step. The
connecting step may comprise connecting to a conductive separator
disposed within the housing.
[0008] In one embodiment, a method of manufacturing a capacitor
comprises the steps of: providing a first and a second capacitor
cell; providing a capacitor housing; coupling the first capacitor
cell to the second capacitor cell; inserting the first capacitor
cell and the second capacitor cell into the housing. The coupling
step may comprise coupling two jellyroll type capacitor cells
together. The two jellyroll type capacitors cells may be coupled to
a conductive separator.
[0009] These and other features and aspects of the present
invention will be better understood with reference to the following
description, figures, and appended claims.
FIGURES
[0010] FIG. 1 illustrates a cross-sectional view of a capacitor
cell positioned within a capacitor housing;
[0011] FIG. 2 illustrates a top cross-section of a jellyroll
configured capacitor cell;
[0012] FIG. 3 illustrates a cross-sectional view of a battery form
factor sized capacitor;
[0013] FIG. 4a illustrates a side cross-sectional view of a
capacitor housing used for holding two series connected capacitor
cells, and FIG. 4b illustrates in schematic form the electrical
circuit formed thereby;
[0014] FIG. 5a illustrates a charge balancing circuit used with two
series connected capacitor cells connected in series within a
housing, and FIG. 5b illustrates in schematic form the electrical
circuit formed thereby;
[0015] FIG. 6 illustrates an embodiment, wherein a sealed capacitor
product is manufactured such that charge balancing circuit is
shielded from unnecessary or unwanted end user interaction;
[0016] FIG. 7a illustrates a side cross-sectional view of a
capacitor housing used for holding two capacitor cells used in a
parallel configuration and, FIG. 7b illustrates in schematic form
the electrical circuit formed thereby.
DESCRIPTION
[0017] FIG. 1 illustrates a cross-sectional view of a capacitor
cell positioned within a capacitor housing. In one embodiment, a
capacitor cell 11 comprises collectors and electrodes disposed on
either side of the collectors. The capacitor cell 11 in FIG. 1 is
formed in a configuration known to those skilled in the art as a
"jellyroll", where offset collectors, electrodes, and separators
are rolled to form the jellyroll. In one embodiment, the jellyroll
is formed about a support rod. In a jellyroll configuration,
longitudinal edges of the offset collectors 15, 16 extend from the
jellyroll in opposing directions. In one embodiment, after rolling,
the support rod is removed from the jellyroll to leave a centrally
disposed void 18. In one embodiment, capacitor cell 11 is
positioned within a housing 13, for example, a can, a tube, or a
cylinder open at one end and sealed or closed at another end. The
capacitor cell 11 is positioned such that edges of a collector 16
extending from one end of the jellyroll butt up against a sealed or
closed end or bottom 17 of the housing 13. In one embodiment, a
resistive contact and connection between the collector 16 and the
bottom 17 may be improved by soldering, welding, or otherwise
attaching the collector 16 to the bottom 17. In one embodiment, one
end of a spot welder is positioned through the void 18 at or near
the bottom 17, and the edges of collector 16 are subsequently
welded to the bottom 17. In one embodiment, edges of collector 15
at an opposite end of the rolled capacitor 11 are attached to a
sealing cap 19. In one embodiment, the collector 15 is attached to
sealing cap 19 by welding. In other embodiments, collectors 15, 16
may be attached by many other different techniques known to those
skilled in the art, for example: laser welding, conductive glues,
soldering, mechanical attachment, brazing, to name a few. In one
embodiment, sealing cap 19 is attached to the housing 13 with an
insulating seal 56 disposed therebetween. The sealed housing 13 is
subsequently impregnated with an electrolyte through a fill hole
(not shown). In one embodiment, the insulating seal 56 provides
electrically insulates the sealing cap 19 from housing 13 as well
as prevents the electrolyte from escaping from within the sealed
housing.
[0018] FIG. 2 illustrates a cross-section of a jellyroll configured
capacitor cell. As viewed from an end in a cross-section, in one
embodiment, a capacitor cell 11 comprises two collectors 15, 16.
Each collector 15, 16 is offset in a perpendicular direction to
that of the crossection such that edges of one collector extend in
one direction and such that edges of the other collector extend on
the opposite direction. The collectors 15, 16 each have disposed on
each of their sides an electrode film (not shown). The collectors
and electrode film combinations are separated by separators 19, 20,
the combination of which is rolled to form a jellyroll type
capacitor cell 11.
[0019] FIG. 3 illustrates a cross-sectional view of a battery form
factor sized capacitor. In one embodiment, a jellyroll configured
capacitor cell 31 is disposed and impregnated within housing 33 to
provide a finished capacitor product 30 that conforms to the
dimensions of a D sized battery form factor. Various battery form
factor sized capacitors are disclosed in commonly assigned U.S.
patent application Ser. No. 10/766,727, filed 27 Jan. 2004, DKT.#
M101US, which is incorporated herein by reference.
[0020] Because a capacitor cell 31 comprised of double-layer
capacitor technology is limited by its physics and chemistry to a
maximum operating voltage of about 4 volts, a single double-layer
capacitor product provided in a housing, for example, a battery
form factor sized housing 33, would also be limited to a maximum
operating voltage of about 4 volts. Furthermore, because the
nominal operating voltage of double-layer capacitor cells is
typically about 2.7 volts, the nominal operating voltage of a
single cell double layer capacitor product 30 provided in a battery
form factor sized housing 33 would also be about 2.7 volts. In one
embodiment, a jellyroll double-layer capacitor cell disposed within
a housing 33 can provide about 500 Farads of capacitance at about
2.7 volts.
[0021] FIG. 4a illustrates a side cross-sectional view of a
capacitor housing used for holding two capacitor cells, and FIG. 4b
illustrates in schematic form the electrical circuit formed
thereby. In one embodiment, as viewed from each end, a capacitor
housing 43 comprises an open-ended cylinder or tube that defines a
double open-ended housing. In other embodiments, housing 43 may
comprise, as viewed from an end, an elongated, rectangular, square,
rectangular, or other geometry. In one embodiment, housing 43
comprises opposing open ends 43a, 43b. In one embodiment, the
housing 43 comprises a centrally disposed inner sealing portion 44.
Portion 44 effectuates a sealed inner separation of the housing 43,
such that the housing can be used to functionally separate two
capacitor cells 41, 42 disposed therein. In one embodiment, the
housing 43 and the sealing portion 44 comprise a conductor or the
like, for example, a metal such as aluminum. When in contact, it is
understood that the conductive housing 43 and a conductive sealing
portion 44 may be electrically connected. The housing 43 and/or
portion 44 can be manufactured by one or more techniques known to
those skilled in the art, for example, by molding, by extrusion, by
deep draw, by physical insertion of the sealing portion, by
coupling two single open-ended housings together at their closed
ends, etc. In one embodiment, wherein two single open-ended
housings are coupled together at their closed end, the sealing
portion 44 would comprise the combination of the two closed ends.
Those skilled in the art will, thus, understand that the structure
comprised of housing 43 and portion 44 could be formed as one
integral piece, or as two or more separate connected pieces. In one
embodiment, capacitor cells 41, 42 comprise double-layer capacitor
cells configured as jellyrolls, wherein edges of collectors 45, 46
extend from ends of the capacitors. In one embodiment, a first
capacitor cell 41 and a second capacitor cell 42 are each formed by
rolling offset collectors, electrodes disposed on the collectors,
and separators separating the electrodes, about a support rod. In
one embodiment, the support is removed after rolling, leaving
respective voids 48 in the capacitor cells 41, 42. In one
embodiment, the first capacitor cell 41 is disposed into one open
end 43a of the housing 43, and the second capacitor cell 42 is
disposed into a second open end 43b of the housing 43, such that
the inward edges of collectors 46 extending from respective ends of
the first and the second capacitor cells 41, 42 electrically
contact a respective opposing side or surface of the sealing
portion 44.
[0022] Contact between collectors 46 and sealing portion 44 can be
improved by connecting the edges of collectors 46 to a respective
side or surface of sealing portion 44. In one embodiment, the
housing 43 comprises sealing caps 48a, 48b. In one embodiment, the
outward edges of collectors 45 of capacitor cells 41 and 42 are
connected to respective sealing caps 48a, 48b. In one embodiment,
improved connection of inner edges of collectors 46 may be
effectuated by a welder placed in a void 48 of a respective
capacitor cell 41, 42 at or near the inner edges of the collectors
that butt up against the sealing portion 44. In one embodiment, the
welder may be placed in each void 48 of each capacitor cell 41, 42
at or near the collectors 46, and the collectors 46 of both cells
may be welded to the separator in one connection step. It is
identified that connection of two capacitor cells together within
housing 43 in one process step enables improved process
efficiencies that lower manufacturing cost. It is understood, that
although edges of collectors 45 and/or 46 may be electrically
contacted to a respective sealing portion 44 and sealing caps 48a
or 48b using techniques known generically as welding, the use of
this term is not meant to be limiting as other techniques for
accomplishing low resistance connections can also be used, for
example, spot welding, laser welding, conductive gluing, brazing,
mechanical attachment, to name a few. In one embodiment, one or
both of the sealing caps 48a, 48b may be attached to the housing 43
at respective open ends 43a, 43b, where electrically non-conductive
seals 43c are disposed between the sealing caps and the housing 43.
In one embodiment, one or both sealing caps 48a-b may include a
connecting electrode 49 or terminal of a configuration appropriate
for effectuating external connection to the sealing caps.
[0023] FIG. 5a illustrates a charge balancing circuit used with two
series connected capacitor cells and a housing, and FIG. 5b
illustrates in schematic form the electrical circuit formed
thereby. It is identified that two or more capacitor cells
connected in series may be operated at a higher voltage than one
capacitor cell alone. Thus, two or more series connected
double-layer capacitor cells could be operated at voltages above
the about 4 volt limitation of a single capacitor cell, for
example, up to about 8 v (twice the rating of one cell), allowing a
series combination of double-layer capacitors to be used in a wider
range of applications than a single double-layer capacitor cell. In
an application wherein two double-layer capacitor cells rated for a
nominal operating voltage of about 2.7 volts are connected in
series, those skilled in the art would identify that that a nominal
operating voltage the series combination could be used at about 5.4
volts, a voltage at which many more circuits and devices are know
to operate and higher than that available from one double-layer
capacitor cell. Accordingly, it is identified that a double
open-ended capacitor housing as described herein may be used to
facilitate series connection of two double-layer capacitor cells
and, thus, to provide such a series combination of cells in
applications requiring higher voltages than about 2.7 volts.
Furthermore, it is identified that a double open-ended housing
could be provided in a battery form factor sized housing, for
example, as a D cell form factor sized housing, with each capacitor
cell within the housing sized appropriately to fit within the
housing.
[0024] It is identified that in some applications, for example,
when two double-layer capacitor cells are connected in series, the
application may require that the voltage V applied across the
capacitors be equally distributed. A balancing circuit 70 is now
capable of being manufactured very cheaply (on the order of cents)
and in a very small form factor, for example as an ASIC, an
encapsulated semiconductor die, or the like, thus allowing it to be
used unobtrusively in many applications. One or more embodiment of
a charge balancing circuit 70 is described in commonly assigned
U.S. application Ser. No. 10/423,708, DKT.# M104US, which is
incorporated herein by reference.
[0025] In one embodiment, a charge balancing circuit 70 is coupled
to two series connected capacitor cells 71, 72, and the cells are
disposed within a double open-ended capacitor housing 73. In one
embodiment, the housing 73 comprises a sealing portion 78. In one
embodiment, the edges of inner collectors 77 of capacitor cells 71,
72 are electrically coupled by sealing portion 78 to form a series
connection thereby. In one embodiment, the capacitor cells 71, 72
are coupled to portion 78 after sealing portion is formed within or
inserted into housing 73. In one embodiment, the capacitor cells
71, 72 are coupled to sealing portion 78 before the portion is
inserted into housing 73. In one embodiment, the capacitor cells
71, 72 may be coupled to sealing portion 78 outside of the housing
33, and subsequently inserted within the housing 33. It is
identified that connection of two jellyroll capacitor cells
together at a sealing portion in one process step enables improved
process efficiencies that lower manufacturing cost. In one
embodiment, edges of inner collectors 77 are connected to portion
78 by a conductive glue, spot welding, laser welding, soldering,
brazing, mechanical attachment, or other similar connection means.
In one embodiment, housing 73 comprises sealing caps 88a, 88b. In
one embodiment, edges of outer collectors 75 can also be coupled to
respective sealing caps 88a, 88b using one or more techniques
described herein previously, for example, by spot welding,
conductive glues, laser welding, brazing, soldering, etc. In one
embodiment, both sealing caps 88a, 88b may be coupled to housing 73
by an insulating seal 88c disposed therebetween.
[0026] In one embodiment, ends of the charge balancing circuit 70
may be electrically coupled to the sealing caps 88a, 88b. In one
embodiment, charge balancing circuit 70 is coupled electrically to
outer collectors 75 through the connection of sealing caps 88a, 88b
thereto, and is coupled to inner collectors 77 through electrical
connection via the conductive housing 73 and sealing portion 78. In
one embodiment, one or both sealing caps 88a-b, may comprise a
terminal 79 for effectuating external connection to the housing
73.
[0027] FIG. 6 illustrates an embodiment, wherein a sealed capacitor
product 99 may be manufactured such that charge balancing circuit
70 is shielded from unnecessary or unwanted end user interaction.
In embodiments wherein use of a charge balancing circuit 70 is
provided for safety reasons, use of a preconnected charge balancing
circuit 70 within an enclosure 90 would obviate the need for
instructing end users as to proper connection and use of the charge
balancing circuit. In one embodiment, the enclosure may therefore
comprise a shrink wrap type plastic covering or other suitable
material or suitable housing that may be used to shield the
capacitor housing 73 and or circuit 70 from end user interaction.
Use of an enclosure 90 could therefore facilitate use of housing 73
in an off the shelf pre-connected manner. However, in some
applications wherein a charge balancing circuit 70 is provided, a
charge balancing circuit may not be necessary. Thus, in one
embodiment, one or more disconnect may be provided for selective
enabling or disabling of the charge balancing circuit 70. In one
embodiment, selective enabling or disabling could be provided by
one or more connection, for example, one or more switch connection
92, 93, 94 (shown in an open condition) that permits selective
on/off connections between the charge balancing circuit 70 and
capacitor cells 71, 72.
[0028] FIG. 7a illustrates a side cross-sectional view of a
capacitor housing used for holding two capacitor cells, and FIG. 7b
illustrates in schematic form the electrical circuit formed
thereby. It is identified that two or more capacitor cells
connected in parallel may be operated at a higher capacitance than
one capacitor cell alone. Accordingly, it is identified that one or
more aspects of a double open-ended capacitor housing as described
herein may be used to facilitate parallel connections of two
capacitor cells and, thus, to provide such a parallel combination
of cells for applications requiring higher capacitance than
possible with one capacitor cell. Furthermore, it is identified
that a double-open-ended housing could be provided in a battery
form factor sized housing, for example, as a D cell form factor
sized housing, with each capacitor cell within the housing sized
appropriately to fit within the housing.
[0029] In one embodiment, a housing 173 comprises a centrally
disposed inner sealing portion 178 comprised of conductive portion
178a and insulative portion 178b, wherein sealing portion 178b acts
to electrically insulate the conductive portion 178a from the
housing 173. Portion 178 effectuates a sealed inner separation of
the housing 173, such that the housing can be used to separately or
simultaneously house two capacitor cells 171, 172. In one
embodiment, the housing 173 and the sealing portion 178a comprise a
conductor or the like, for example, a metal such as aluminum. The
housing 173 and portion 178 can be manufactured by one or more
techniques known to those skilled in the art, for example, by
molding, by extrusion, by deep draw, by physical insertion of the
sealing portion, etc. In one embodiment, capacitor cells 171, 172
comprise double-layer capacitor cells configured as jellyrolls,
wherein edges of collectors 175, 177 extend from ends of the
capacitors. In one embodiment, the first capacitor cell 171 is
disposed into one open end of the housing 173, and the second
capacitor cell 172 is disposed into a second open end of the
housing, such that the inward edges of collectors 177 extending
from respective ends of the first and the second capacitor cells
171, 172 electrically contact a respective opposing side or surface
of the conductive sealing portion 178a and, thus, each other. The
collectors 177 may be subsequently electrically connected to
sealing portion using one or more of the methods previously
described herein. The housing 173 also includes two sealing caps
188a, to which the collectors 175 may also be electrically
connected. The sealing caps 188a, 188b may be sealable coupled to
the housing 173 such that an electrical connection is made between
collectors 175 of capacitor cells 171 and 172. In one embodiment,
the capacitor housing 173 also includes a conductive connection 170
to the conductive sealing portion 178a. Those skilled in the art
will identify that an electrical connection could be made to
connection 170 and to a terminal 179 in manner that the parallel
capacitance of cells 171 and 172 could be utilized. In one
embodiment, the conductive connection 170 is made through an
insulated sealable hole made in an appropriate part of the housing
173. In one embodiment, it is envisioned that the connection 170
could be provided through a sealable fill hole used to impregnate
one or both of the capacitor cells 171, 172 with electrolyte.
[0030] While the particular systems and methods herein shown and
described in detail are fully capable of attaining the above
described object of this invention, it is understood that the
description and drawings presented herein represent some, but not
all, embodiments of the invention and are therefore representative
of the subject matter which is broadly contemplated by the present
invention. For example other dimension, other form factors, other
types of capacitors and other energy storage devices, for example
battery cells, could be adapted and used with one or more
embodiments disclosed herein. Thus, the present invention should
accordingly limited by nothing other than the appended claims and
their legal equivalents.
* * * * *