WHITE PAPER

DESIGN CONSIDERATIONS FOR ULTRACAPACITORS

Maxwell Technologies, Inc.

Maxwell Technologies, Inc. Maxwell Technologies SA Maxwell Technologies GmbH Maxwell Technologies, Inc. -
Worldwide Headquarters CH-1728 Rossens Brucker Strasse 21 Shanghai Representative Office
9244 Balboa Avenue Switzerland D-82205 Gilching Rm.2104, Suncome Liauws Plaza
San Diego, CA 92123 Phone: +41 (0)26 411 85 00 Germany 738 Shang Cheng Road
USA Fax: +41 (0)26 411 85 05 Phone: +49 (0)8105 24 16 10 Pudong New Area
Phone: +1 858 503 3300 Fax: +49 (0)8105 24 16 19 Shanghai 200120, P.R. China
Fax: +1 858 503 3301 Phone: +86 21 5836 5733
[email protected] www.maxwell.com Fax: +86 21 5836 5620
MAXWELL TECHNOLOGIES WHITE PAPER:
Design in Guide

Maxwells BOOSTCAP ultracapacitors are increasingly being utilized in consumer

electronics, traction, automotive, telecoms and industrial, with applications including
pulse power, bridge power, main power and memory backup. This document provides an
overview of some of the key performance characteristics and design issues of BOOSTCAP
ultracapacitors. Product datasheets, tools for sizing ultracapacitors to an application,
application notes and white papers are available at our website (www.maxwell.com). It is
recommended to contact Maxwell for assistance and more detailed information before
commencing any design. Maxwell is committed to RoHS compliance and providing
product satisfying Directive (2002/95/EC) limiting use of hazardous substances in
electrical and electronic components, as well as complying with all relevant safety and
quality standard. Please contact Maxwell for more information.

1. Temperature effects and performance changes over time

The performance of Maxwell Technologies ultracapacitors is very stable over a wide

operating temperature due to the chemistry and physical make up of the products. An
advantage of the ultracapacitors organic based electrolyte is its low freezing point. This
enables the ultracapacitors to be utilized over a wide range of temperatures, with
relatively unaffected performance. Plots of capacitance and resistance change as a
function of temperature are available on request.

2. Lifetime

Ultracapacitor life is predominantly affected by a combination of operating voltage and

operating temperature. The ultracapacitor has an unlimited shelf life when stored in a
discharged state. When referring to ultracapacitor life the data sheets reflect the change
in performance, typically decrease in capacitance and increase in resistance. The
ultracapacitor does not experience a true end of life rather the performance continually
degrades over the life of the use of the product.

The typical degradation behavior of the ultracapacitor resembles that of an exponential

decay. The majority of the performance change occurs during the initial use of the
ultracapacitor and this performance change then levels off over time. The most dramatic
effect of the life degradation is on the internal resistance of the device.

In many applications, such as UPS, the ultracapacitors will be maintained at working

voltage until needed. Plots are available on request that show the degradation in rated
capacitance for ultracapacitors held at typical working voltages for long periods of time,
and at different temperatures. To give one example, a 15% reduction in rated

Maxwell Technologies, Inc. Maxwell Technologies SA Maxwell Technologies GmbH Maxwell Technologies, Inc. -
Worldwide Headquarters CH-1728 Rossens Brucker Strasse 21 Shanghai Representative Office
9244 Balboa Avenue Switzerland D-82205 Gilching Rm.2104, Suncome Liauws Plaza
San Diego, CA 92123 Phone: +41 (0)26 411 85 00 Germany 738 Shang Cheng Road
USA Fax: +41 (0)26 411 85 05 Phone: +49 (0)8105 24 16 10 Pudong New Area
Phone: +1 858 503 3300 Fax: +49 (0)8105 24 16 19 Shanghai 200120, P.R. China
Fax: +1 858 503 3301 Phone: +86 21 5836 5733
[email protected] www.maxwell.com Fax: +86 21 5836 5620
MAXWELL TECHNOLOGIES WHITE PAPER:
Design in Guide

capacitance and a 40% increase in rated resistance may occur for an ultracapacitor held
at 2.5 V after 88,000 hrs at 25 o C. The plots, along with the fact that the influence of
temperature has a doubling effect for every 10 o C, can be used to predict the expected
performance change for a variety of conditions.

3. Cycling

From cycle testing performed on the products, under typical conditions the product is
expected to provide in excess of 1 million duty cycles with an approximate 20% reduction
in rated capacitance. More details of the testing and plots of capacitance versus cycles
are available on request.

4. Frequency response

Ultracapacitors have a typical time constant of approximately one second. One time
constant reflects the time necessary to charge a capacitor 63.2% of full charge or
discharge to 36.8% of full charge.

The time constant of an ultracapacitor is much higher than that of an electrolytic

capacitor. Therefore, it is not possible to expose ultracapacitors to a continuous ripple
current as overheating may result. The ultracapacitor can respond to short pulse power
demands, but due to the time constant the efficiency or available energy is reduced.

5. Voltage

Ultracapacitors are capable of operating between their rated voltage and zero volts.
Occasional spikes above the rated voltage will not immediately affect the capacitor.
Depending on the frequency and duration of voltage spikes the life will be reduced.

Efficient utilization of the available energy and power storage is achieved with the widest
operating voltage range use. Most electronics have a minimum voltage threshold for
utilization, limiting the effective utilization voltage of the capacitor although there is no
limitation in the capacitor itself. Since the energy in the capacitor is proportional to the
voltage squared according to E = C V 2 .

It is possible to utilize approximately 75% of the available energy if the application

utilizes from the rated voltage to rated voltage of the capacitor.

Maxwell Technologies, Inc. Maxwell Technologies SA Maxwell Technologies GmbH Maxwell Technologies, Inc. -
Worldwide Headquarters CH-1728 Rossens Brucker Strasse 21 Shanghai Representative Office
9244 Balboa Avenue Switzerland D-82205 Gilching Rm.2104, Suncome Liauws Plaza
San Diego, CA 92123 Phone: +41 (0)26 411 85 00 Germany 738 Shang Cheng Road
USA Fax: +41 (0)26 411 85 05 Phone: +49 (0)8105 24 16 10 Pudong New Area
Phone: +1 858 503 3300 Fax: +49 (0)8105 24 16 19 Shanghai 200120, P.R. China
Fax: +1 858 503 3301 Phone: +86 21 5836 5733
[email protected] www.maxwell.com Fax: +86 21 5836 5620
MAXWELL TECHNOLOGIES WHITE PAPER:
Design in Guide

6. Polarity

Unlike many batteries the anode and cathode of an ultracapacitor are comprised of the
same material. If the positive and negative terminal and casing are also comprised of
similar materials, then theoretically the ultracapacitor has no true polarity.

For manufacturing and consistency purposes the terminals are marked with polarity. It is
recommended practice to maintain the polarity although catastrophic failure will not
occur if the ultracapacitor is reversed charged for some reason. If the ultracapacitor has
been conditioned for charge in a certain direction and then is changed, the life can be
reduced due to this conditioning. For the PC5, PC10 and PC55 products the case is
comprised of stainless steel. Due to the corrosion potential it is required to maintain the
polarity indicated on the products, and reverse polarity will cause accelerated life
reduction.

7. Charging

Since the energy storage mechanism of the ultracapacitor is not a chemical reaction,
charging/discharging of the ultracapacitors can occur at the same rate. Therefore, the
rated current for the ultracapacitor applies for both charge and discharge. The efficiency
of charge and discharge are in practical terms the same. A variety of methods are
possible for charging of the ultracapacitors. This may be either through constant current
or constant power charging via a dc source or through ac charging methods. A separate
application note is available discussing different methodologies for ultracapacitor
charging.

8. Series connection and balancing

Since the individual ultracapacitor cell voltage is relatively limited compared to the
majority of application requirements, it is necessary to series connect the ultracapacitors
to achieve the voltage required. Because each ultracapacitor will have a slight tolerance
in capacitance and resistance it is necessary to balance, or prevent, individual
ultracapacitors from exceeding its rated voltage.

Balancing can be achieved through two different methods, active balancing or passive
balancing:

Active balancing schemes are varied. Maxwell has adopted a balancing methodology
based on a linear voltage balancing scheme. This methodology will always attempt

Maxwell Technologies, Inc. Maxwell Technologies SA Maxwell Technologies GmbH Maxwell Technologies, Inc. -
Worldwide Headquarters CH-1728 Rossens Brucker Strasse 21 Shanghai Representative Office
9244 Balboa Avenue Switzerland D-82205 Gilching Rm.2104, Suncome Liauws Plaza
San Diego, CA 92123 Phone: +41 (0)26 411 85 00 Germany 738 Shang Cheng Road
USA Fax: +41 (0)26 411 85 05 Phone: +49 (0)8105 24 16 10 Pudong New Area
Phone: +1 858 503 3300 Fax: +49 (0)8105 24 16 19 Shanghai 200120, P.R. China
Fax: +1 858 503 3301 Phone: +86 21 5836 5733
[email protected] www.maxwell.com Fax: +86 21 5836 5620
MAXWELL TECHNOLOGIES WHITE PAPER:
Design in Guide

to balance two adjoining ultracapacitors based on the voltage mismatch between

the two ultracapacitors. The maximum current during balancing varies by product.
Refer to the product data sheet or product manual for more information.

Passive balancing implies no variation in the voltage regulation as a function of the

ultracapacitor condition. The most typical method of passive balancing utilizes
resistors in parallel with the ultracapacitors.

A variety of interconnect methods are employed with the various product offerings. They
range from buss bar interconnecting to soldering. In general the larger the cell
capacitance the more critical the cell interconnects becomes. The larger capacitance
devices have internal resistances on the order of a few hundred microohms. A poor
interconnection can have more resistance than the internal resistance of the device itself.
Larger devices will generally be required to carry larger currents, thus necessitating
reliable interconnects.

9. Efficiency

Unlike batteries, the ultracapacitor has the same efficiency during charge or discharge.
This enables the ultracapacitor to be recharged quickly without current limiting as long as
the current is within the rated current for the device.

The only efficiency losses associated with ultracapacitors are due to internal resistance of
the device resulting in IR drop during cycling. For most uses the ultracapacitor efficiency
is in excess of 98%. For high current or power pulsing the efficiency is reduced. Typical
efficiency under high current pulses is still greater than 90%.

10. Thermal Properties

For minimum performance influence over the life of the application it is necessary to
maintain the ultracapacitor core temperature within the rated temperature range of the
device. The lower the temperature is maintained the better for life considerations.

All products are provided with an electrically insulating shrink sleeving around the
capacitor body. For this reason and since all current passes through the capacitor
terminals, cooling at the capacitor ends or terminals is the most efficient means for
cooling of the capacitor.

Maxwell Technologies, Inc. Maxwell Technologies SA Maxwell Technologies GmbH Maxwell Technologies, Inc. -
Worldwide Headquarters CH-1728 Rossens Brucker Strasse 21 Shanghai Representative Office
9244 Balboa Avenue Switzerland D-82205 Gilching Rm.2104, Suncome Liauws Plaza
San Diego, CA 92123 Phone: +41 (0)26 411 85 00 Germany 738 Shang Cheng Road
USA Fax: +41 (0)26 411 85 05 Phone: +49 (0)8105 24 16 10 Pudong New Area
Phone: +1 858 503 3300 Fax: +49 (0)8105 24 16 19 Shanghai 200120, P.R. China
Fax: +1 858 503 3301 Phone: +86 21 5836 5733
[email protected] www.maxwell.com Fax: +86 21 5836 5620
MAXWELL TECHNOLOGIES WHITE PAPER:
Design in Guide

Depending on the duty cycle of the application cooling can be accomplished via heat
sinks (conduction), air flow (convection) or a combination of the two. Consideration
should be made for the duty cycle and resulting capacitor temperature as well as the
anticipated ambient temperature the device will be operating under. The combination of
the two should not exceed the operating temperature for the ultracapacitor.

More information and advice on thermal performance and design considerations is

provided for each product on the data sheet.

Maxwell Technologies, Inc. Maxwell Technologies SA Maxwell Technologies GmbH Maxwell Technologies, Inc. -
Worldwide Headquarters CH-1728 Rossens Brucker Strasse 21 Shanghai Representative Office
9244 Balboa Avenue Switzerland D-82205 Gilching Rm.2104, Suncome Liauws Plaza
San Diego, CA 92123 Phone: +41 (0)26 411 85 00 Germany 738 Shang Cheng Road
USA Fax: +41 (0)26 411 85 05 Phone: +49 (0)8105 24 16 10 Pudong New Area
Phone: +1 858 503 3300 Fax: +49 (0)8105 24 16 19 Shanghai 200120, P.R. China
Fax: +1 858 503 3301 Phone: +86 21 5836 5733
[email protected] www.maxwell.com Fax: +86 21 5836 5620