logging system

专利摘要:
PRODUCTION LOG REGISTRATION INSTRUMENT. The present invention relates to a logging system and method for operating a logging system that is typically used in a well bore. The logging system may include a logging instrument that includes a rechargeable energy storage and logging electronics and a cable configured to slow rechargeable energy storage. Rechargeable energy storage can include an ultracapacitor. Rechargeable energy storage can be subjected to slow charging via the cable from a remote power source.
公开号:BR112014010635B1
申请号:R112014010635-5
申请日:2012-11-05
公开日:2020-12-29
发明作者:Riccardo Signorelli；John J. Cooley；Morris Green；Padmanaban Sasthan Kuttipillai；Jenna McGrath；Christopher John Sibbald Deane；Ira M. Turner
申请人:Fastcap Systems Corporation；
IPC主号:

专利说明:

CROSS REFERENCE TO RELATED ORDERS
[0001] This request claims priority based on Provisional Application under No. 61 / 555,100 filed on November 3, 2011 and Provisional Application under No. 61 / 624,080 filed on April 13, 2012, which are incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION Field of the Invention
[0002] The invention disclosed in this document relates to exploration for oil and gas and, in particular, to a well-bottom instrument for the production of well logging. Description of the Related Art
[0003] In oil and gas exploration, it is necessary to drill a well in the earth. The assessment of the land and the surrounding formations is often undertaken with the use of sophisticated tools lowered into the wellbore. Assessments, or well logging, can be completed during drilling (measurement during drilling, (MWD or LWD)) or after drilling, such as lowering a steel cable.
[0004] A variety of instruments can be used. Instruments that are targeted at technologies such as radiation measurement (gamma and neutron generation) and measurements that involve acoustics, seismic, resistivity, magnetic resonance, are often used as fluid sampling and various other forms of spectroscopy. Unfortunately, the various tools and instruments that are useful for logging the well generally involve intricate equipment that requires a connection to a power supply and another topside of auxiliary equipment. Therefore, the logging equipment is removed from the well before a well goes into production.
[0005] However, the removal of logging equipment from a well leaves operators in a situation where it is impossible to characterize rock bottom resources. Consequently, operators periodically stop production to conduct logging of the well and assess the health of the respective production well. Obviously, the cessation of production has a major financial impact on the operator.
[0006] Therefore, adequate methods and devices are needed to conduct well logging in a production environment. Preferably, the methods and apparatus should provide a variety of types of analysis with minimal impact on production. BRIEF SUMMARY OF THE INVENTION
[0007] An instrument for performing downhole measurements during the production of a well includes: inspection components, a communications channel, downhole electronic components and a power block. The power block supplies power to the production logging instrument. The power pack may include a generator, a power supply connection (such as a topside power supply), a primary battery, and a high temperature rechargeable energy storage. Ultracapacitors can be used for energy storage
[0008] According to a first aspect of the invention, a method for operating a logging system comprises: subjecting to a slow charge a rechargeable energy storage for a first period of time; and operation of electronic logging components using the power of the rechargeable energy storage for a second period of time that is shorter than the first period of time.
[0009] According to a second aspect of the invention, a method for operating a logging system comprises: subjecting to slow loading a rechargeable energy storage of a logging instrument located in a well bore; and operation of electronic logging components of the logging instrument using the power of the rechargeable energy storage for selected periods of time.
[00010] According to a third aspect of the invention, a logging system comprises: a logging instrument that includes a rechargeable energy storage, a cable and electronic components configured to charge the rechargeable energy storage from a remote power source.
[00011] According to a fourth aspect of the invention, a logging instrument comprises: electronic logging components configured to perform a logging operation; and a rechargeable energy storage configured to receive a slow charge from a remote power source and to supply power to the logging electronics for selected periods of time.
[00012] According to a fifth aspect of the invention, a logging instrument comprises: electronic logging components configured to perform a logging operation and one or more sensors selected from sensor types including pressure, temperature , coating collar locator, accelerometer, acoustic density, seismic, embedded and caged flow meters, solid state flow meters, capacitance, inductance, resistivity, acoustic reception and / or transmission, passive range, active range, fluid sampling , formation sampling, magnetic resonance imaging, nuclear magnetic resonance, inertial or directional sensors, magnetic sensors and gyroscopes; and a high temperature rechargeable energy storage configured to supply power to the electronic logging components.
[00013] According to a sixth aspect of the invention, a method for operating a logging system comprises: moving a logging instrument vertically in a well by means of a cable that holds the logging instrument mechanically and provides information transmission and / or power transmission, in which the logging instrument comprises a high temperature rechargeable energy storage.
[00014] According to a seventh aspect of the invention, a method for operating a logging system comprises: moving a logging instrument vertically in a well for at least a period of time by means of a cable supporting the logging instrument and provides information transmission and / or power transmission; and retaining the logging instrument in a fixed position in the well for a second period of time, wherein the logging instrument comprises a high temperature rechargeable energy storage.
[00015] According to an eighth aspect of the invention, a distributed logging system comprises: a plurality of logging instruments arranged in different locations within a well, in which at least one of the logging instruments comprises a high temperature rechargeable energy storage.
[00016] According to a ninth aspect of the invention, a logging system comprises: a power input that includes a primary battery, a remote source and / or a generator; a high temperature rechargeable energy storage; and a charge to receive energy from the rechargeable energy storage. BRIEF DESCRIPTION OF THE DRAWINGS
[00017] The matter that is considered as the invention is particularly highlighted in the specification. The foregoing features and other features and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[00018] Figure 1 illustrates an exemplary embodiment of a drilling column that includes a logging instrument;
[00019] Figure 2 illustrates an exemplary modality for logging a well with an instrument positioned by a steel cable;
[00020] Figure 3 represents an exemplary modality for logging the well with a production logging instrument;
[00021] Figure 4 represents components of the production logging instrument of Figure 3;
[00022] Figure 5 represents an exemplary configuration that uses a plurality of production logging instruments;
[00023] Figure 6 represents another modality of the production logging instrument;
[00024] Figure 7 represents another modality of the production logging instrument;
[00025] Figure 8 illustrates aspects of an exemplary ultracapacitor;
[00026] Figure 9 represents modalities of primary structures for cations that can be included in the exemplary ultracapacitor;
[00027] Figure 10 represents a modality of a housing for the exemplary ultracapacitor;
[00028] Figure 11 illustrates an embodiment of a storage cell for the exemplary capacitor;
[00029] Figure 12 represents a barrier arranged over an internal portion of a housing body;
[00030] Figures 13A and 13B, collectively referred to in the present document as Figure 13, represent aspects of a termination for the accommodation;
[00031] Figure 14 represents an assembly of the ultracapacitor according to the teachings in this document;
[00032] Figures 15A and 15B, collectively referred to herein as Figure 15, are graphs that represent the performance for the ultracapacitor for a modality without a barrier and a similar modality that includes the barrier, respectively;
[00033] Figure 16 represents the barrier arranged on the storage cell as an enclosure;
[00034] Figures 17A, 17B and 17C, collectively referred to herein as Figure 17, represent termination modalities that include multilayered materials;
[00035] Figure 18 is a cross-sectional view of an electrode assembly that includes a glass seal to the metal;
[00036] Figure 19 is a cross-sectional view of the electrode assembly of Figure 18 installed at the termination of Figure 17B;
[00037] Figure 20 represents an arrangement of the energy storage cell in the assembly process;
[00038] Figures 21A, 21B and 21C, collectively referred to herein as Figure 21, represent modalities of an assembled energy storage cell;
[00039] Figure 22 represents the use of polymeric insulation on the electrode assembly;
[00040] Figures 23A, 23B and 23C, collectively referred to in this document as Figure 23, represent aspects of a model for another type of termination for energy storage;
[00041] Figure 24 is a perspective view of an electrode assembly that includes hemispherically shaped material;
[00042] Figure 25 is a perspective view of a termination that includes the electrode assembly of Figure 24 installed in the model of Figure 23C;
[00043] Figure 26 is a cross-sectional view of the termination in Figure 25;
[00044] Figure 27 is a transparent isometric view of the energy storage cell arranged in a cylindrical housing;
[00045] Figure 28 is an isometric perspective view of an embodiment of the energy storage cell before being laminated into a laminated storage cell;
[00046] Figure 29 is a side view of the storage cell, showing several layers of an embodiment;
[00047] Figure 30 is an isometric perspective view of a laminated storage cell that includes a reference mark for placing a plurality of fillets;
[00048] Figure 31 is an isometric perspective view of the storage cell of Figure 30 with reference marks before being laminated;
[00049] Figure 32 represents the laminated storage cell with the plurality of fillets included;
[00050] Figure 33 represents a Z-fold provided in aligned threads (that is, a terminal) coupled to the storage cell;
[00051] Figures 34 to 42 are graphs that represent performance aspects for exemplary ultracapacitors;
[00052] Figure 43 represents a modality of a power supply that includes the generator and the ultracapacitor;
[00053] Figures 44 to 50 represent modalities of control circuits for the power supply. DETAILED DESCRIPTION
[00054] Various configurations of a production logging instrument adapted for use in a downhole environment are disclosed in this document. The production logging instrument provides users with logging information during the production of a well. In order to provide context for the production logging instrument and methods for use, some background information and definitions are provided.
[00055] Refer now to Figure 1 and that the aspects of an apparatus for drilling a well hole 1 (also called a "drilled hole") are shown. As a matter of convention, a depth of well hole 1 is described along a geometry axis Z, while a cross section is provided in a plane described by a geometry axis X and a geometry axis Y.
[00056] In this example, well hole 1 is drilled into earth 2 with the use of a drill column 11 driven by a probe (not shown) that, among other things, provides rotational energy and downward force. Well hole 1 generally passes through subsurface materials, which may include several formations 3 (shown as formations 3A, 3B, 3C). A person skilled in the art will recognize that the various geological features as they can be found in a subsurface environment can be called "formations," and that the arrangement of materials at the bottom of the drilled hole (ie, the bottom of the well) can be called of "subsurface materials." That is, formations 3 are formed of subsurface materials. Consequently, as used in this document, it should be considered that although The term "formation" refers generally to geological formations and "subsurface material," it includes any materials and can include materials such as solids, fluids, gases, liquids and the like .
[00057] In this example, the drill column 11 includes extensions of drill pipe 12 that drives a drill 14. The drill 14 also provides a flow of drilling fluid 4, such as drilling mud. Drilling fluid 4 is pumped frequently into drill bit 14 through drilling tube 12, where fluid exits into well hole 1. This results in an upward flow of drilling fluid 4 into well hole 1. The flow ascending cools the drilling column 11 and its components in general, takes away cuttings from drill bit 14 and prevents the eruption of pressurized hydrocarbons 5.
[00058] Drilling fluid 4 (also called "drilling mud") generally includes a mixture of liquids such as water, drilling fluid, mud, oil, gases and formation fluids as may be indigenous to the surrounding areas. . Although drilling fluid 4 can be introduced for drilling operations, the use or presence of drilling fluid 4 is neither required nor necessarily excluded from well logging operations. In general, a layer of materials will exist between an outer surface of the drill column 11 and a wall of the well hole 1. This layer is called a "separator layer," and includes a thickness, called a "separator, S."
[00059] Drill column 11 generally includes equipment to perform "measurement during drilling" (MWD), also called "logging during drilling" (LWD). The realization of MWD or LWD in general refers to the operation of a logging instrument 10 that is incorporated in the drilling column 11 and designed for operation during drilling. In general, the logging instrument 10 for performing MWD is coupled with a package of electronic components that is also incorporated in the drill column 11 and therefore is called "downhole electronic components 13." In general, downhole electronic components 13 provide at least one among data collection, data analysis and operational control such as electromechanical performance (s), communications, power processing and the like. Often, the logging instrument 10 and downhole electronic components 13 are coupled to the topside equipment 7. The topside equipment 7 can be included to further control operations, provide greater analysis capabilities as well as logging data and the like. A communications channel (discussed below) can provide communications to topside equipment 7 and by operating through pulsed mud, wired tube, EM telemetry, fiber optics and other technologies as are known in the art and are practicable for a given application .
[00060] Referring now to Figure 2, an exemplary logging instrument 10 for logging steel cable from well hole 1 is shown. As a matter of convention, a well hole depth 1 is described along a geometry axis Z, while a cross section is provided in a plane described by a geometry axis X and a geometry axis Y. Before logging the well with the logging instrument 10, the well hole 1 is drilled in the ground 2 with the use of a drilling rig, as shown in Figure 1.
[00061] In some embodiments, well hole 1 was filled, at least to some extent, with drilling fluid 4. Drilling fluid 4 (also called "drilling mud") generally includes a mixture of liquids such as water, drilling fluid, mud, oil, gases and formation fluids as may be indigenous to the surroundings. Although drilling fluid 4 can be introduced for drilling operations, the use or presence of drilling fluid 4 is neither required nor necessarily excluded from logging operations during wire rope logging. In general, a layer of materials will exist between an external surface of the logging instrument 10 and a wall of the well hole 1. This layer is called a "separator layer," and includes a thickness, called a "separator, S. "
[00062] A compartment 21 can be inserted into well hole 1 to ensure physical integrity. The compartment can be formed in the well hole 1, inserted therein, or otherwise arranged in the well hole 1. The compartment 21 can be segmented or continuous. For purposes of discussion in this document, compartment 21 generally includes several cementitious outer compartment facilities 21, as well as internal production piping (such as production piping).
[00063] In general, in steel cable logging, the logging instrument 10 is recessed in the well hole 1 using a steel cable 8 positioned by a crane 6 or similar equipment. In general, steel cable 8 includes a suspension apparatus, such as a load-bearing cable, as well as another apparatus. The other device may include a power supply, a communications link (such as wired or optical) and other similar equipment. In general, the steel cable 8 is transported from a service truck 9 or similar device (such as a service station, a base station, etc., ...). Often, the steel cable 8 is coupled to the topside equipment 7. The topside equipment 7 can supply power to the logging instrument 10, as well as provide processing and computing capabilities for at least one of the operations control and analysis of the Dice.
[00064] In permanent logging, the logging instrument can be transported into the well hole in several ways. In some embodiments, the logging instrument is "piped" meaning that at least a portion of the logging instrument is attached to a portion of the production pipe prior to insertion into the well bore. When the pipe is inserted into the well hole, the logging instrument is transported with it. In some embodiments, the logging instrument is carried by the steel cable, that is, it is lowered into the well hole in a similar way as in the steel cable logging. In some embodiments, the logging instrument is "carried by compartment" meaning that at least a portion of the logging instrument is attached to a portion of the production compartment prior to insertion into the well bore. Other methods of transport are possible as determined by the designer. Both pipeline and steel cable transportation accommodate readjustment projects although compartment transportation generally requires that the logging instrument be installed during well completion.
[00065] In general, a permanent logging instrument can be connected to a permanent well bottom cable (PDC). A PDC can be a single or multiple conductors. Each conductor can be solid or strung. The conductors can be isolated, encapsulated, shielded, or some combination thereof. Multiple conductors can be twisted or configured coaxially. The cable can be designed for the transmission of electricity, power, information or both; it can also be designed to support a substantial mechanical load, for example in steel cable transport modes.
[00066] In some modalities, the power is transmitted to the production logging instrument 100 through a fiber optic cable. An exemplary device for supplying power through fiber is provided by RLH Industries of Orange, California and sold as a "Fiber Power System (PoF).
[00067] The electronic components 13 can include at least one among a power converter, a controller, a processor and the like. In general, the electronic components 13 provide control power from the power block 44 to at least one of the communication channel 43 and the inspection components 15. The electronic components 13 can initiate energy conservation measures, such as through shutdown of at least one of communications channel 43 and inspection components 15. Energy conservation (also called "sleep state" or "sleep mode") can be initiated when a power condition (such as a state of charge) on power block 44 does not meet a desired limit.
[00068] In some embodiments, electronic components 13 regulate the discharge of power from a plurality of types of energy storage 42. For example, electronic components 13 can extract power from at least one ultracapacitor to satisfy the initial boot load that it may be associated with some devices (such as a mud pulse 43 communications channel). Therefore, electronic components 13 can provide a "smooth start", thereby accentuating a lifetime of at least one battery in the energy storage 42.
[00069] The electronic components 13 can condition the power of the power block 44 as appropriate. For example, electronic components 13 can simulate the power produced by a given type of supply (for example, it can simulate the power supplied by a battery while extracting from an ultracapacitor); electronic components 13 can buffer power, pulse power and otherwise generally provide power in a manner considered appropriate.
[00070] In general, the logging instrument 10 includes an apparatus for performing "downhole" or wellhole 1 measurements. This apparatus includes, for example, a variety of inspection components 15. Exemplary inspection components 15 may include radiation detectors, shielding, sensors, transducers and many of the other various inspection components 15 known in the art. Components 15 can communicate with downhole electronics 13 as appropriate. Measurements and other sequences that can be performed using the logging instrument 10 are generally performed to ascertain and qualify the presence of hydrocarbons 5.
[00071] Referring now to Figure 3, an exemplary production logging instrument 100 is shown. The production logging instrument 100 can be deposited inside well bore 1, where it is left after other equipment is withdrawn. The production logging instrument 100 can be deposited in the pit using other equipment, such as a tractor (not shown). In some embodiments, the production logging instrument 100 may include elements from a tractor (such as an engine and rail), so that the production logging instrument 100 is self-placing.
[00072] Once production is started, drilling fluid 4 is expelled from well hole 1. A flow of hydrocarbons 5 is established. During production initiation, a wellhead 30 is placed over wellbore 1. Wellhead 30 provides flow regulation from wellbore 1 and accommodates extended periods of hydrocarbon extraction 5. As shown by the upward arrow , when the production logging instrument 100 is in place, production (hydrocarbon withdrawal 5) can continue without decreasing.
[00073] Referring now to Figure 4, the components of an exemplary production logging instrument 100 are shown. In this example, the production logging instrument 100 includes inspection components 15, a communications channel 43, downhole electronic components 13, and a power block 44. Power block 44 provides power to the production logging 100.
[00074] The power source 401 which is included in the power supply 115 may include a variety of power inputs. Power inputs can, in general, be divided into three categories. The categories include primary batteries, remote systems and generators.
[00075] Generator 41 may include a generator added by flow (such as one driven by production flow). For example, generator 41 may include a rotating generator, a vibrational energy generator (such as displacement generator types), or other types of power generators. Other types of power generation devices can be used alone or in combination with each other. Exemplary generator types include, without limitation, rotary generators, electromagnetic displacement generators, magnetostrictive displacement generators, piezoelectric displacement generators, thermoelectric generators, thermophotovoltaic generators and may include connections to remote generators, such as a steel cable connection to a wire generator or power supply that is maintained topside. These generators are well known in the industry. In general, an output from generator 41 is regulated by downhole electronics 13. However, the output can be regulated on board generator 41, thus enabling a direct connection from generator 41 to energy storage 42. Energy storage Example 42 includes various forms of batteries, ultracapacitors and the like. In some embodiments, the energy storage 42 (and / or other components of the production logging instrument 100) are replaceable and can be exchanged during a downhole maintenance evolution with, for example, a cable tool. steel that provides remote manipulations by an operator.
[00076] An exemplary communications channel 43 includes components to provide EM telemetry, in which signals can be transported through compartment 21 and / or surroundings through the use of electric, magnetic or electromagnetic fields. Likewise, the communications channel can be operated through compartment 21 (specifically, for example, through metallic production piping or through the use of compartment 21 as a waveguide). Communications can be carried out with pulsed fluids, through optical channels, through wired systems and through other techniques as may be known in the art, or developed later.
[00077] Some modalities of the production logging instrument 100 include those arranged in a housing that is an annular cylinder, then accommodating the flow through the production logging instrument 100. Other modalities may include a solid cylindrical shape with a small cross-sectional area (that is, a small diameter). The production logging instrument 100 may include extendable arms or other components (not shown) that assist with, for example, downhole placement and / or retention. In short, the production logging instrument 100 can, in general, be of any physical form desired by designers, manufacturers, operators and the like.
[00078] In some modalities the logging instrument is transported with the aid of a "carrier" - a section specially designed for the production pipeline that carries the logging instrument as the production pipeline is inserted into the hole well. The carrier is an annular cylinder that accommodates flow through its center portion. The carrier can be designed to affix a logging instrument as one that has a solid cylindrical shape. Alternatively, the logging instrument can be designed as part of the carrier. In both cases, the carrier can be designed to allow logging instrument access to both the inside of the production piping and the outer ring. Access through the production pipeline wall can be accommodated by means of a "door" incorporated in the carrier - a mechanical or other passive operation of the carrier for the transmission of various parameters, whether electrical, thermal, pressure related, or otherwise.
[00079] As mentioned above, an exemplary energy storage 42 includes an ultracapacitor. In some embodiments, the energy storage 42 is adapted for high temperature operation (for example, up to about 210 degrees Celsius). Other components that can be used in energy storage 42 include, for example, rechargeable batteries, reversible fuel cells and the like. In summary, various energy storage modalities 42 include forms suitable for operation at an elevated temperature and exhibit a long service life. An exemplary ultracapacitor is described later in this document in relation to Figure 8.
[00080] In some embodiments, the production logging equipment 100 is adapted for use without energy storage 42 (or with a failed energy storage 42). In some of these modalities, the power of other components of the power block 44 is used to energize the downhole electronic components 13 and other components that need power.
[00081] The downhole logging instrument 100 can be used as a stand-alone system, in combination with other downhole logging instruments 100 (such as to provide local measurements as well as data passing among others. downhole logging instruments 100), or in any provision deemed appropriate. In some embodiments, it may be desired to delete communications channel 43 and to simply use the production logging instrument 100 as a logging device that is retrieved later. In these modalities, data can be downloaded from the production logging instrument 100 since the production logging instrument 100 is topside.
[00082] In general, the modalities of the production logging instrument 100 are equipped to ascertain at least one among ambient temperature, flow rate, ambient pressure, induced and / or ambient radiation levels (for example, gamma), resistivity, fluid density, fluid capacitance, fluid dielectric properties and porosity of surrounding formations 3.
[00083] In some embodiments, the power supply connection 45 includes a wired connection to a topside power supply. In some embodiments, wireless (EM) signals (such as a very low frequency signal) can be used to transmit power, wherein the production logging instrument 100 includes a receiver for receiving power. In additional modalities, the wire rope or wired compartment can be used to transmit power. In some additional modes, a waveguide (such as compartment 21) can be relied on to provide power transmission.
[00084] Referring now to Figure 5, an exemplary configuration that uses a plurality of production logging instruments 100 is shown. In this example, the plurality of production logging instruments 100 is distributed within well bore 1. A first type of production logging instrument 100 is placed at the bottom of well bore 1. Advantageously, this type can be include components that are not conveniently placed at an intermediate location in the well bore 1. For example, a production logging instrument of the bottom type 100 may include additional energy storage 42, additional inspection components 15, and / or other types of generators 41 that are not conveniently arranged in an intermediate location in the well bore 1. A second type of production logging instrument 100 (for convenience, called "intermediate type", or by other similar terms) it is used. In this example, both types of production logging instrument 100 are rigidly arranged inside the compartment. One embodiment of a device for arranging the production logging instrument 100 within compartment 21 includes, for example, a centralizer 69. The intermediate type can be designed to have a small cross-sectional area and therefore provide minimal reductions in the production or flow of hydrocarbons 5.
[00085] The intermediate production logging instrument 100 can be used to provide logging of wells at locations along a length of well bore 1. This can be useful to, among other things, characterize or identify the depletion of hydrocarbons 5 in the surrounding land 2. Additionally, each of the intermediate production logging instruments 100 can be equipped with bidirectional communications, so that each respective intermediate production logging instrument 100 can pass data from another instrument of production logging 100 along well 1, finally to a topside receiver. This last modality can be used, for example, to improve the reliability, reach and / or bandwidth of communications.
[00086] An example of the production logging instrument 100 is shown in greater detail in relation to Figure 6.
[00087] Referring now to Figure 6, a modality of the production logging instrument 100 is shown. In this example, the production logging instrument 100 includes a plurality of generators 41 (i.e., rotary type generators). The flow of hydrocarbons 5 into the well bore 1 is directed to a cover that surrounds the turbine blades and causes the generator 41 to produce power. After flowing through the turbine blades, the flow exits through side vents 71 and continues to ascend along the borehole 1. In this modality, the production logging instrument 100 can be conveniently and reliably centralized into well bore 1 by means of a centralizer 69 (as shown in Figure 6).
[00088] When a plurality of generators 41 is included in the production logging instrument 100 (some modalities include only one generator 41), the flow of hydrocarbons 5 can be guided around each of the generators 41. That is, a set of side vents 71 can be provided, which correlate with each of the generators 41. Each set of side vents 71 generally includes a plug (such as a rotating plug, not shown) to close the respective side vents 71. Consequently, an operator can selectively operate each of generators 41 (or electronic components 13 can be configured to automatically switch between generators 41). Therefore, as each of the generators 41 reaches the end of a useful life, another one of the generators 41 can be put into service, thereby providing a long life of the production logging instrument 100.
[00089] Referring now to Figure 7, another modality of the production logging instrument 100 is shown. Once placed locally, the production logging instrument 100 starts logging and tracks values for various parameters. In this embodiment, the production logging instrument 100 includes a modular communications channel 43 that includes a plurality of physically separable and distinct elements (i.e., modules 81). Communications occur at periodic intervals, such as once a month, when the production logging instrument 100 downloads associated data in one of the plurality of modules 81. Each module 81 can include, for example, a power supply (like a ceramic capacitor), a memory (like a micro-SD card, or equivalent) and a remote identification device (like a radio frequency identification marker (RFID) (or antenna)). Each of modules 81 can be coupled to the production logging instrument 100 via a bus 82. In general, bus 82 includes components to distribute power and communicate with each of modules 81. Additionally, bus 82 includes a plurality of releases (such as electromechanical or electromagnetic release devices) to selectively release each of the modules 81.
[00090] As each interval ends, the production logging instrument 100 ensures that the set of relevant data is stored in the selected memory, for example, it can energize a respective module among the plurality of modules 81 by loading the power source. built-in power, programming the memory (that is, downloading data to memory) and then releasing module 81 in the hydrocarbon flow 5. The flow then carries module 81 together to the wellhead 30. Once the released module 81 approaches the wellhead 30 in which the extraction of hydrocarbons 5 is carried out, remote identification of the module 81 is carried out. For example, an RFID receiver (not shown) will detect the RFID tag (not shown). Once detected, a detection signal can be sent to an operator and / or an automated system (such as a motor-operated valve) to divert module 81 to a recovery point.
[00091] Once the module 81 is retrieved by the operator, the data can then be downloaded. Advantageously, data of very high granularity (data resulting from frequent sampling and / or sampling of various properties and parameters) can be obtained from the well. Additionally, the data can be correlated with other wells, such as other nearby wells. Consequently, the production dynamics for an oil field can then be characterized. This gives producers insight into the development of additional wells, depletion of existing wells and other insights into production activities.
[00092] In some embodiments, the communications channel 43 includes an optical fiber element (not shown). The fiber optic element can be used to communicate directly from the production logging instrument 100 with a topside fiber optic signal receiver. The fiber optic element can also be used as an interferometer and provide users with other data that can be collected from it. An exemplary modality of a fiber optic interferometer is provided in Patent Application under No. U .: 12 / 368,576, entitled "Fiber Optic Sensor System Using White Light Interferometry", which is incorporated by reference in this document in its entirety.
[00093] As an overview, power supply 115 generally includes electrical storage and a generator to generate electrical output. Energy storage can include any type of practicable technology. In various embodiments, the energy storage includes at least one ultracapacitor (which is described below with reference to Figure 3). In general, in each case, the energy storage provides a High Temperature Rechargeable Energy Storage (HTRES). In some embodiments, HTRES is configured to operate at a temperature that is within a temperature range between about 80 degrees Celsius to about 210 degrees Celsius.
[00094] Additional HTRES modalities include, without limitation, chemical batteries, aluminum electrolytic capacitors, tantalum capacitors, ceramic and metal film capacitors, hybrid capacitors, magnetic energy storage, for example, inductors of core material of high temperature or air core. Other types that may also be suitable include, for example, mechanical energy storage devices, such as flywheels, spring systems, mass-spring systems, mass systems, thermal capacity systems (for example those based on solids or liquids high thermal capacity or phase change materials), pneumatic or hydraulic systems. An example is the high temperature hybrid capacitor available from Evans Capacitor Company Providence, RI USA, part number HC2D060122 DSCC10004-16 rated at 125 degrees Celsius. Another example is the high temperature tantalum capacitor available from Evans Capacitor Company Providence, RI USA, part number HC2D050152HT rated at 200 degrees Celsius. Yet another example is an aluminum electrolytic capacitor available from EPCOS Munich, Germany, part number B41691A8107Q7, which is rated at 150 degrees Celsius. Yet another example is the inductor available from Panasonic Tokyo, Japan, part number ETQ-P5M470YFM rated at 150 degrees Celsius. Additional modes are available from Saft, Bagnolet, France (part number Li-ion VL 32600-125) that operates up to 125 degrees Celsius with 30 charge-discharge cycles, as well as an operable li-ion (experimental) battery up to about 250 degrees Celsius and experimentally with Sadoway, Hu, from Solid Energy in Cambridge, Massachusetts.
[00095] For the sake of discussion, the 115 power supply modalities discussed in this document involve the use of a high temperature ultracapacitor, however, this is not a limitation of the technologies that can be included in the energy storage of the power supply 115. The exemplary aspects of an ultracapacitor suitable for use as high temperature energy storage are now introduced.
[00096] A capacitor that provides users with improved performance over a wide temperature range is revealed in this document. For example, the capacitor can be operable at temperatures ranging from about as low as minus 40 degrees Celsius to as high as about 210 degrees Celsius. In some embodiments, the capacitor is operable at temperatures ranging from about 80 degrees Celsius to as high as about 210 degrees Celsius.
[00097] In general, the capacitor includes the energy storage medium that is adapted to provide high power density and high energy density when compared to prior art devices. The capacitor includes components that are configured to ensure operation over the temperature range and includes any one or more of a variety of electrolyte forms that are similarly classified for the temperature range. The combination of construction, energy storage medium and electrolyte results in the ability to provide robust operation under extreme conditions. To provide some perspective, aspects of an exemplary modality are now introduced.
[00098] As shown in Figure 8, an example of a capacitor is shown. In this case, the capacitor is an "ultracapacitor 210." The exemplary ultracapacitor 210 is an electric double layer capacitor (EDLC). EDLC includes at least one pair of electrodes 203 (where electrodes 203 can be called individually as one of a "negative electrode 203" and a "positive electrode 203," however, this is for reference purposes only in this document) . When mounted on ultracapacitor 210, each of the electrodes 203 has a double charge layer on an electrolyte interface. In some embodiments, a plurality of electrodes 203 are included (for example, in some embodiments, at least two pairs of electrodes 203 are included). For discussion purposes, only one pair of 203 electrodes is shown. As a matter of convention in this document, at least one of the electrodes 203 uses a carbon-based energy storage medium 201 (as further discussed in this document) to provide energy storage. However, for purposes of discussion in this document, it is generally assumed that each of the electrodes includes the 201 carbon-based energy storage medium. It should be noted that an electrolytic capacitor differs from an ultracapacitor because, in a electrolytic capacitor, metal electrodes typically differ greatly (at least an order of magnitude) in the area.
[00099] Each of the electrodes 203 includes a respective current collector 202 (also called "charge collector"). In some embodiments, electrodes 203 are separated by a separator 205. In general, separator 205 is a thin structural material (usually a blade) used to separate negative electrode 203 from positive electrode 203. Separator 205 can also serve to separate pairs of electrodes 203. Once assembled, electrodes 203 and separator 205 provide a storage cell 212. Note that, in some embodiments, the carbon-based energy storage medium 201 may not be included in one or both electrodes 203. That is, in some embodiments, a respective electrode 203 may consist only of current collector 202. The material used to supply current collector 202 could be coarse, anodized or the like to increase its surface area. In these embodiments, current collector 202 alone can serve as electrode 203. With that in mind, however, as used herein, The term "electrode 203" generally refers to a combination of the energy storage medium 201 and current collector 202 (but this is not limiting, for at least the previous reason).
[000100] At least one form of electrolyte 206 is included in ultracapacitor 210. Electrolyte 206 fills empty spaces in and between electrodes 203 and separator 205. In general, electrolyte 206 is a substance that dissociates into electrically charged ions. A solvent that dissolves the substance can be included in some embodiments of the 206 electrolyte, as appropriate. Electrolyte 206 conducts electricity by ionic transport.
[000101] In general, storage cell 212 is formed into one of a rolled or prismatic shape which is then packaged in a prismatic or cylindrical housing 207. Once electrolyte 206 has been included, housing 207 can be hermetically sealed . In several instances, the packaging is hermetically sealed by techniques that use laser, ultrasonic, and / or welding technologies. In addition to providing robust physical protection for storage cell 212, housing 207 is configured with external contacts to provide electrical communication with respective terminals 208 within housing 207. Each of terminals 208, in turn, provides electrical access to the energy stored in the energy storage medium 201, generally through electrical threads that are coupled to the energy storage medium 201.
[000102] As discussed in this document, "hermetic" refers to a seal whose quality (ie leak rate) is defined in units of "atm-cc / second," which means one cubic centimeter of gas (for example , He) per second in ambient temperature and atmospheric pressure. This is equivalent to an expression in units of "standard He-cc / s." Additionally, it is recognized that 1 atm-cc / s is equal to 1.01325 mbar-liter / second. In general, the ultracapacitor 210 disclosed in this document has the ability to provide an airtight seal that has a leakage rate not greater than about 5.0x10-6 atm-cc / s and can exhibit a leakage rate no greater than about 5.0x10-10 atm-cc / s. It is also considered that the performance of a successful hermetic seal should be judged by the user, designer or manufacturer as appropriate and that "hermetic" ultimately implies a standard that must be defined by a user, designer, manufacturer or other interested third party.
[000103] Leak detection can be performed, for example, through the use of a tracking gas. Using tracking gas as helium for leak testing is advantageous since it is a dry, fast, accurate and non-destructive method. In an example of this technique, the ultracapacitor 210 is placed in a helium environment. The ultracapacitor 210 is subjected to pressurized helium. The ultracapacitor 210 is then placed in a vacuum chamber that is connected to a detector that has the ability to monitor the presence of helium (as an atomic absorption unit). With the knowledge of the pressurization time, pressure and internal volume, the leak rate of the ultracapacitor 210 can be determined.
[000104] In some embodiments, at least one fillet (which can also be called "flap" in this document) is electrically coupled to a respective current collector 202. A plurality of the fillets (in accordance with the polarity of the ultracapacitor 210) can be grouped together and coupled to a respective terminal 208. In turn, terminal 208 can be coupled to an electrical access, called a "contact (for example, one of the 207 housing and an external electrode (also called the present document by "pass" or "pin" convention)). Reference can be made to Figures 18, 19 and 20. Now consider the energy storage medium 201 in more detail.
[000105] In the exemplary ultracapacitor 210, the energy storage medium 201 is formed of carbon nanotubes. The energy storage medium 201 may include other carbonaceous materials which include, for example, activated carbon, carbon fibers, rayon, graphene, airgel, carbon cloth and a plurality of forms of carbon nanotubes. Activated carbon electrodes can be manufactured, for example, by producing a carbon-based material by performing a first activation treatment for a carbon material obtained by carbonizing a carbon compound, producing a formed body by adding if a binder to the carbon-based material, carbonizing the formed body and finally producing an active carbon electrode, performing a second activation treatment for the carbonized formed body. Carbon fiber electrodes can be produced, for example, using preformed cloth or paper with high surface area carbon fibers.
[000106] In an exemplary method for manufacturing carbon nanotubes, an apparatus for producing an aligned carbon nanotube aggregate includes an apparatus for synthesizing the carbon nanotube aggregate aligned in a base material that has a catalyst on a surface thereof. The apparatus includes a forming unit which processes a forming step which makes an environment surrounding the catalyst a environment of a reducing gas and heating at least the catalyst or reducing gas; a growth unit that processes a growth stage of synthesis of the aligned carbon nanotube aggregate making the environment surrounding the catalyst an environment of a raw material gas and heating at least the catalyst or material gas gross; and a transfer unit that transfers the base material from at least the forming unit to the growth unit. A variety of other methods and apparatus can be employed to provide the aligned carbon nanotube aggregate.
[000107] In some embodiments, the material used to form the energy storage medium 201 may include a material in addition to pure carbon (and the various forms of carbon as it may currently exist or be further developed). That is, several formulations of other materials can be included in the energy storage medium 201. More specifically and as a non-limiting example, at least one binder material can be used in the energy storage medium 201, however, this is not for suggest or require the addition of other materials (such as binder material). In general, however, the energy storage medium 201 is substantially formed of carbon and can therefore be referred to herein as "carbonaceous material," as a "carbonaceous layer" and in other similar terms. In summary, although formed predominantly of carbon, the energy storage medium 1 can include any form of carbon (as well as any additives or impurities as deemed appropriate or acceptable) to provide a desired functionality as an energy storage medium 201.
[000108] In a set of embodiments, the carbonaceous material includes at least about 60% elemental carbon by weight and in other embodiments at least about 75%, 85%, 90%, 95% or 98% by weight of carbon elementary.
[000109] The carbonaceous material can include carbon in a variety of forms, including carbon black, graphite and others. The carbonaceous material may include carbon particles, which include nanoparticles, such as nanotubes, nanorods, blade sheets of graphene, and / or formed in cones, rods, spheres (magnetic spheres) and the like.
[000110] Some embodiments of various forms of carbonaceous material suitable for use in energy storage medium 201 are provided herein as examples. These modalities provide robust energy storage and are well suited for use on the 203 electrode. It should be noted that these examples are illustrative and do not limit the modalities of carbonaceous material suitable for use in the energy storage medium 201.
[000111] In general, the term "electrode" refers to an electrical conductor that is used to make contact with another material that is often non-metallic, in a device that can be incorporated into an electrical circuit. In general, The term "electrode," as used in this document, is with reference to current collector 202 and additional components that may accompany current collector 202 (such as energy storage medium 201) to provide the desired functionality (for example, the energy storage medium 201 which corresponds to the current collector 202 to provide energy storage and energy transmission).
[000112] Turning to the current collector 202, in some embodiments, the current collector 202 is between about 0.5 micrometers (μm) to about 25 micrometers (μm) in thickness. In some embodiments, the current collector 202 is between about 20 micrometers (μm) to about 40 micrometers (μm) thick. The current collector 202 may look like a thin layer, like the layer that is applied by chemical vapor deposition. (CVD), ion bombardment, electronic beam, thermal evaporation or through another suitable technique. In general, the current collector 202 is selected for its properties as conductivity, being electrochemically inert and compatible with the energy storage medium 201 (e.g., CNT). Some exemplary materials include aluminum, platinum, gold, tantalum, titanium and can include other materials as well as various alloys.
[000113] Once the current collector 202 is joined to the energy storage medium 201 (e.g., CNT), an electrode element 215 is realized. Each electrode element 215 can be used individually as electrode 203, or it can be coupled to at least another electrode element 215 to provide electrode 203.
[000114] The 205 separator can be manufactured from various materials. In some embodiments, the separator 205 is non-woven glass. The 205 separator can also be manufactured from fiberglass, ceramics and fluorine polymers, such as polytetrafluoroethylene (PTFE), commonly marketed as TEFLONTM by DuPont Chemicals of Wilmington, DE, USA. For example, with the use of non-woven glass, separator 5 can include main fibers and binding fibers, each having a smaller fiber diameter than that of each of the main fibers and allowing the main fibers to be bonded each other.
[000115] For the longevity of ultracapacitor 210 and to ensure high temperature performance, separator 205 should have a reduced amount of impurities and in particular, a very limited amount of hydration contained therein. In particular, it has been observed that a limitation of about 200 ppm of hydration is desired to reduce chemical reactions and improve the life span of the ultracapacitor 210 and to provide good performance in high temperature applications. Some types of materials for use in the 205 separator include polyamide, polytetrafluoroethylene (PTFE), polyetheretherketone (PEEK), aluminum oxide (Al2O3), fiberglass and glass-reinforced plastic (GRP).
[000116] In general, the materials used for the 205 separator are chosen according to a hydration content, porosity, melting point, impurity content, resulting electrical performance, thickness, cost, availability and the like. In some embodiments, the separator 205 is formed of hydrophobic materials.
[000117] Consequently, procedures can be employed to ensure that excess hydration is eliminated from each 205 separator. Among other techniques, a vacuum drying procedure can be used.
[000118] Note that, in some embodiments, ultracapacitor 210 does not require or include separator 205. For example, in some embodiments, such as when electrodes 203 are assured of physical separation by construction geometry, it is sufficient to have electrolyte 206 alone between electrodes 203. More specifically, and as an example of physical separation, such an ultracapacitor 210 may include electrodes 203 that are arranged within a housing so that separation is ensured on a continuous basis. An example of a bench would include an ultracapacitor 210 provided in a beaker.
[000119] The ultracapacitor 210 can be incorporated in several different factors (that is, it displays a certain appearance). Examples of potentially useful shape factors include, a cylindrical cell, a ring-shaped or annular cell, a flat prismatic cell or a stack of flat prismatic cells comprising a box-like cell and a flat prismatic cell that is shaped to accommodate a particular geometry as a curved space. A cylindrical form factor can be most useful in conjunction with a cylindrical tool or a tool mounted on a cylindrical form factor. A ring-shaped or annular form factor may be most useful in conjunction with a tool that is ring-shaped or mounted on a ring-shaped form factor. A flat prismatic cell shaped to accommodate a particular geometry can be useful for making effective use of "dead space" (ie, space in a tool or equipment that is otherwise unoccupied and can be generally inaccessible).
[000120] Although generally disclosed herein in terms of a "jelly roll" application (i.e., a storage cell 212 that is configured for a cylindrically shaped housing 207), the laminated storage cell 223 can take any shape desired. For example, in position to laminate storage cell 212, flexing of storage cell 212 can be performed to provide laminated storage cell 223. Other types of mounting can be used. As an example, storage cell 212 may be a flat cell, called a "coin type" cell. Consequently, lamination is merely an option for mounting the laminated storage cell 223. Therefore, although discussed herein in terms of being a "laminated storage cell 223", this is not limiting. The term "laminated storage cell 223" can generally be considered to include any appropriate form of packaging or packaging of the storage cell 212 to fit well within a given housing design 207.
[000121] Various shapes of the ultracapacitor 210 can be joined together. The various shapes can be joined using known techniques, such as welding contacts together, through the use of at least one mechanical connector, placing contacts in electrical contact with each other and the like. A plurality of ultracapacitors 210 can be electrically connected in at least one of them in a parallel and in series form.
[000122] Electrolyte 206 includes a pairing of cations 209 and anions 211 and may include a solvent. Electrolyte 206 can be called "ionic liquid" as appropriate. Various combinations of cations 209, anions 211 and solvent can be used. In the exemplary ultracapacitor 210, cations 209 can include at least one of 1- (3-cyanopropryl) -3-methylimimidazolium, 1,2-Dimethyl-3-propylimimidazolium, 1,3-Bis (3-cyanopropril) imimidazolium, 1, 3- Dietoxyimimidazolium, 1-butyl-1-methylpiperidinium, 1-butyl-2,3-dimethylimimidazolium, 1-butyl-3-methylimimidazolium, 1-butyl-4-methylpyridinium, 1-butylpyridinium, 1-decyl-3-methylimimidazole, 1-ethyl-3-methylimimidazolium, 3-methyl-1-propylpyridinium and combinations thereof as well as other equivalents as deemed appropriate. Additional exemplary cations 209 include imimidazolium, pyrazinium, piperidinium, pyridinium, pyrimidinium and pyrrolidinium (whose structures are shown in Figure 4). In the exemplary ultracapacitor 210, anions 211 may include at least one of bis (trifluoromethanesulfonate) imide, methis tris (trifluoromethanesulfonate), dicyanamide, tetrafluoroborate, hexafluorophosphate, trifluoromethanesulfonate, bis (pentafluoroifluoroethylsulfonyl trifluoroethylsulfonates, trifluoroethylsulfonates) as well as other equivalents as deemed appropriate.
[000123] The solvent may include acetonitrile, amides, benzonitrile, butyrolactone, cyclic ether, dibutyl carbonate, diethyl carbonate, diethyl ether, dimethoxyethane, dimethyl carbonate, dimethylformamide, dimethylsulfone, dioxane, dioxolane, ethyl formate, ethylene carbonate , ethylmethyl carbonate, lactone, linear ether, methyl formate, methyl propionate, methyltetrahydrofuran, nitrile, nitrobenzene, nitromethane, n-methylpyrrolidone, propylene carbonate, sulfolane, sulfone, tetrahydrofuran, tetramethylene sulfone, thiophene, ethylene glycol, diethylene glycol, diethylene glycol, polyethylene glycol, carbonic acid ester, Y-butyrolactone, nitrile, tricianohexane, any combination thereof or other material (s) that exhibit appropriate performance characteristics.
[000124] Referring now to Figure 9, several additional modalities of 209 cations are shown suitable for use in an ionic liquid to supply the 206 electrolyte. These 209 cations can be used alone or in combination with each other, in combination with at least some of the previous 209 cation modalities and can also be used in combination with other 209 cations that are considered compatible and suitable by a similarly interested user, designer, manufacturer or third party. The 209 cations represented in Figure 9 include, without limitation, ammonium, imimidazolium, oxazolium, phosphonium, piperidinium, pyrazinium, pyrazolium, pyridazinium, pyridinium, pyrimidinium, pyrrolidinium, sulfonium, thiazolium, triazolium, guanidium, isoquinoline, benzothriazolium, and violog types functionalized imimidazolium cations.
[000125] Regarding the 209 cations shown in Figure 9, several branching groups (Ri, R2, R3, ... RX) are included. In the case of 209 cations, each branching group (Rx) can be one of alkyl, heteroalkyl, alkenyl, heteroalkenyl, alkynyl, heteroalkynyl, halo, amino, nitro, cyano, hydroxyl, sulfate, sulfonate, or a carbonyl group any of which is optionally replaced.
[000126] The term "alkyl" is recognized in the art and can include saturated aliphatic groups, which include normal chain alkyl groups, branched chain alkyl groups, cycloalkyl (alicyclic) groups, substituted alkyl cycloalkyl groups and substituted cycloalkyl alkyl groups . In certain embodiments, a branched chain or normal chain alkyl has about 20 or less carbon atoms in its main structure (for example, C1-C20 for normal chain, C1-C20 for branched chain). Likewise, cycloalkyls have from about 3 to about 10 carbon atoms in their ring structure and alternatively about 5, 6 or 7 carbons in the ring structure. Examples of alkyl groups include, but are not limited to, methyl, ethyl, propyl, butyl, pentyl, hexyl, ethylhexyl, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl and the like.
[000127] The term "heteroalkyl" is recognized in the art and refers to alkyl groups as described in this document in which one or more atoms is a heteroatom (for example, oxygen, nitrogen, sulfur and the like). For example, the alkoxy group (for example, -OR) is a heteroalkyl group.
[000128] The terms "alkenyl" and "alkynyl" are recognized in the art and refer to unsaturated aliphatic groups analogous in length and possible substitution for the alkyls described above, but which contain at least one double or triple bond respectively.
[000129] The terms "heteroalkenyl" and "heteroalkynyl" are recognized in the art and refer to alkenyl and alkynyl alkyl groups as described herein in which one or more atoms is a heteroatom (for example, oxygen, nitrogen, sulfur and the like ).
[000130] In general, any ion with a negative charge can be used as anion 211. The anion 211 selected is, in general, paired with a large organic cation 209 to form a low temperature fusion ion salt. Room temperature (and lower) fusion salts originate from mainly large 209 anions with a charge of -1. The salts that melt at lower temperatures are, in general, still materialized with anions 211 with electrons easily relocated. Anything that will decrease the affinity between ions (distance, displacement of the charge) will subsequently decrease the melting point. Although possible, anionic formations are virtually infinite, only a subset of these will work in the application of low temperature ionic liquid. This is a non-limiting overview of possible anionic formations for ionic liquids.
[000131] Common substitute groups (α) suitable for use of the 211 anions provided in Table 1 include: -F -, -Cl-, -Br-, -I -, - OCH3 -, -CN-, -SCN- , -C2H3O2 -, -ClO-, -ClO2 -, -ClO3 -, -ClO4 -, -NCO-, - NCS-, -NCSe-, -NCN-, -OCH (CH3) 2 -, -CH2OCH3 -, - COOH-, -OH-, - SOCH3 -, -SO2CH3 -, -SOCH3 -, -SO2CF3 -, -SO3H-, -SO3CF3 -, - O (CF3) 2C2 (CF3) 2O-, -CF3 -, -CHF2 - , -CH2F -, -CH3 - -NO3 -, -NO2 -, -SO3 -, - SO4 2-, -SF5 -, -CB11H12-, -CB11H6Cl6-, -CH3CB11H11-, -C2H5CB11H11-, -APO4 -, - A-SO2 -, AN-SO3 -, -A-SO3H-, -A-COO-, -A-CO- {where A is a phenyl (the phenyl group or phenyl ring is a cyclic group of atoms with the formula C6H5) or substituted phenyl, alkyl, (a radical having the general formula CnH2n + 1, formed by removing a hydrogen atom from an alkane) or substituted alkyl group, negatively charged radical alkanes, (alkanes are chemical compounds which consist only of hydrogen and carbon atoms and are bonded exclusively by single bonds) halogenated alkanes and ethers (which are a class of organic compounds that contain an oxygen atom connected to two alkyl or aryl groups)
[000132] Regarding anions 211 suitable for use in an ionic liquid that supplies electrolyte 206, several organic anions 211 can be used. Exemplary anions 211 and their structures are provided in Table 1. In a first embodiment, (N ° 1), exemplary anions 211 are formulated from the list of substitute groups (α) provided above, or their equivalents. In additional modalities, (Nos. 2 to 5), the exemplary anions 211 are formulated from a respective base structure (Y2, Y3, Y4, ... Yn) and a respective number of anion substitute groups (α1 , α2, α3 ,. αn), in which the respective number of anion substitute groups (α) can be selected from the list of substitute groups (α) provided above, or their equivalents. Note that in some modalities, a plurality of anion substitute groups (α) (ie, at least one different anion substitute group (α)) can be used in any anion 11 modality. Also, note that in some modalities , the base structure (Y) is a single atom or a designated molecule (as described in Table 1), or it can be an equivalent.
[000133] More specifically and by way of example, in relation to the exemplary anions provided in Table 1, certain combinations can be realized. As an example, in the case of No. 2, the base structure (Y2) includes a single structure (for example, an atom, or a molecule) that is linked to two anion substituting groups (α2). Although shown to have two identical anion substitute groups (α2), this need not be the case. That is, the base structure (Y2) can be linked to different anion substitute groups (α2), like any of the anion substitute groups (α) listed above. Similarly, the base structure (Y3) includes a single structure (for example, an atom) that is attached to three anion substituting groups (α3), as shown in case No. 3. Again, each of the substituting groups of anion (α) included in the anion can be varied or diverse and need not repeat (be repetitive or be symmetrical) as shown in Table 1. In general, in relation to the notation in Table 1, a subscript in one of the base structures denotes several connections that the respective base structure can have with anion substitute groups (α). That is, the subscript in the respective base structure (Yn) denotes several annex substitute groups (αn) in the respective anion. Table 1 Exemplary organic anions for an ionic liquid


[000134] The term "cyan" is given its common meaning in the art and refers to the group, CN. The term "sulfate" is given its common meaning in the art and refers to the group, SO2. The term "sulfonate" is given its common meaning in the art and refers to the group, SO3X, where X can be an electron, hydrogen, alkyl or cycloalkyl pair. The term "carbonyl" is recognized in the art and refers to the group, C = O.
[000135] An important aspect for consideration in the construction of ultracapacitor 210 is the maintenance of good chemical hygiene. In order to ensure the purity of the components, in various modalities, the activated carbon, carbon fibers, rayon, carbon cloth, and / or nanotubes that make up the energy storage medium 201 for the two electrodes 203, are dried at temperature high in a vacuum environment. The separator 205 is also dried at elevated temperature in a vacuum environment. Since electrodes 203 and separator 205 are vacuum dried, they are packed in housing 207 without a seal or final termination in an atmosphere with less than 50 parts per million (ppm) of water. The unfinished ultracapacitor 210 can be dried, for example, under vacuum over a temperature range of about 100 degrees Celsius to about 300 degrees Celsius. Once this final drying is complete, electrolyte 206 can be added and housing 207 is sealed in a relatively dry atmosphere (such as an atmosphere with less than about 50 ppm hydration). Obviously, other mounting methods can be used and the previous one provides merely some exemplary aspects of mounting the ultracapacitor 210.
[000136] In general, impurities in electrolyte 206 are kept to a minimum. For example, in some embodiments, a total concentration of halide ions (chloride, bromide, fluoride, iodide), is kept below about 1,000 ppm. A total concentration of metallic species (for example, Br, Cd, Co, Cr, Cu, Fe, K, Li, Mo, Na, Ni, Pb, Zn, which includes at least one of an alloy and an oxide thereof) , is kept below about 1,000 ppm. In addition, the impurities of solvents and precursors used in the synthesis process are kept below about 1,000 ppm and can include, for example, bromoethane, chloroethane, 1-bromobutane, 1-chlorobutane, 1-methylimidazole, ethyl acetate, chloride methylene and so on.
[000137] In some embodiments, the impurity content of ultracapacitor 210 was measured with the use of ion selective electrodes and the Karl Fischer titration procedure, which was applied to electrolyte 206 of ultracapacitor 210. It was observed that the content of total halide in ultracapacitor 210 according to the teachings in this document is less than about 200 ppm of halides (Cl- and F-) and the water content is less than about 100 ppm.
[000138] Impurities can be measured with a variety of techniques, such as, for example, Atomic Absorption Spectrometry (AAS), Inductively Coupled Plasma Mass Spectrometry (ICPMS), or simplified solubilization and electrochemical detection of metal oxide particulates heavy trace. AAS is a spectral-analytical procedure for the quantitative or qualitative determination of chemical elements that employs the absorption of optical radiation (light) by free atoms in the gaseous state. The technique is used to determine the concentration of a particular element (the analyte) in a sample to be analyzed. AAS can be used to determine more than seventy different elements in the solution or directly in solid samples. ICPMS is a type of mass spectrometry that is highly sensitive and has the ability to determine a range of metals and various non-metals in concentrations below one part in 1012 (parts per trillion). This technique is based on the coupling with an inductively coupled plasma as an ion production method (ionization) with a mass spectrometer as an ion separation and detection method. ICPMS also has the ability to monitor the isotopic specification for the ions of choice.
[000139] Additional techniques can be used for the analysis of impurities. Some of these techniques are particularly advantageous for analyzing impurities in solid samples. Ion chromatography (IC) can be used to determine trace levels of halide impurities in electrolyte 206 (for example, an ionic liquid). An advantage of ion chromatography is that the relevant halide species can be measured in a single chromatographic analysis. A Dionex AS9-HC column using an eluent consisting of 20 mM NaOH and 10% (v / v) acetonitrile is an example of a device that can be used for the quantification of halides from ionic liquids. An additional technique is that of X-ray fluorescence.
[000140] X-ray fluorescence (XRF) instruments can be used to measure the halogen content in solid samples. In this technique, the sample to be analyzed is placed in a sample cup and the sample cup is then placed in the analyzer where it is irradiated with X-rays of a specific wavelength. Any halogen atoms in the sample absorb a portion of the X-rays and then reflect the radiation at a wavelength that is characteristic for a given halogen. A detector on the instrument then quantifies the amount of radiation that returns from the halogen atoms and measures the intensity of radiation. Knowing the surface area that is exposed, the concentration of halogens in the sample can be determined. An additional technique for assessing impurities in a solid sample is that of pyrolysis.
[000141] The adsorption of impurities can be measured effectively through the use of pyrolysis and microcoulometers. Microcoulometers have the ability to test almost any type of material for total chlorine content. As an example, a small amount of sample (less than 10 milligrams) is injected or placed in a quartz combustion tube where the temperature ranges from about 600 degrees Celsius to about 1,000 degrees Celsius. Pure oxygen is passed through the quartz tube and any components that contain chlorine are completely burned. The resulting combustion products are swept into a titration cell in which chlorine ions are captured in an electrolyte solution. The electrolyte solution contains silver ions that immediately combine with any chlorine ions and come out of the solution as insoluble ion chloride. A silver electrode in the titration cell electrically replaces the silver ions used until the concentration of silver ions is back where it was before the titration starts. Keeping track of the amount of current required to generate the required amount of silver, the instrument has the ability to determine how much chlorine was present in the original sample. Dividing the total amount of chlorine present by the weight of the sample generates the concentration of chlorine that is currently in the sample. Other techniques for assessing impurities can be used.
[000142] The characterization of surface and water content in electrode 203 can be examined, for example, by infrared spectroscopy techniques. The four main absorption bands around 1,130, 1,560, 3,250 and 2,300 cm-1, correspond to vC = O in, vC = C in aryl, vO - H and vC - N, respectively. By measuring the intensity and peak position, it is possible to quantitatively identify surface impurities inside the 203 electrode.
[000143] Another technique for identifying impurities in electrolyte 206 and ultracapacitor 210 is Raman spectroscopy. The spectroscopic technique depending on the inelastic diffusion, or Raman diffusion, of monochromatic light, usually from a laser in the visible, almost infrared, or almost ultraviolet range. The laser light interacts with molecular vibrations, phonons or other excitations in the system, resulting in the energy of the laser photons being shifted up and down. Therefore, this technique can be used to characterize atoms and molecules within ultracapacitor 210. Several variations of Raman spectroscopy are used and can prove to be useful in characterizing levels in ultracapacitor 210.
[000144] Once the 210 ultracapacitor is manufactured, it can be used in high temperature applications with little or no leakage current and little increase in resistance. The 210 ultracapacitor described in this document can operate effectively at temperatures from minus 40 degrees Celsius to about 210 degrees Celsius with normalized leakage currents throughout the device volume less than 1 amp per liter (A / L) volume of the device within the entire operating voltage and temperature range.
[000145] By reducing the hydration content in ultracapacitor 210 (for example, to less than 500 parts per million (ppm) on the weight and volume of the electrolyte and impurities to less than 1,000 ppm), ultracapacitor 210 can operate effectively over the temperature range, with a leakage current (I / L) that is less than 1,000 mAmp per liter within that temperature range and voltage range.
[000146] In one mode, leakage current (I / L) at a specific temperature is measured by retaining the voltage of the ultracapacitor 210 constant at the rated voltage (that is, the maximum rated operating voltage) for seventy-two hours ( 72). During this period, the temperature remains relatively constant at the specified temperature. At the end of the measurement interval, the leakage current of the ultracapacitor 210 is measured.
[000147] In some embodiments, a maximum voltage rating of the ultracapacitor 210 is about 4 V at room temperature. One approach to ensuring the performance of ultracapacitor 210 at elevated temperatures (for example, above 210 degrees Celsius), is to downgrade (ie, reduce) the voltage rating of ultracapacitor 210. For example, the voltage rating can be decreased to about 0.5 V, so that extended durations of operation at higher temperature are achievable.
[000148] Another method for ensuring a high degree of purity includes an exemplary process for purifying the electrolyte 206. It should be noted that although the process is presented in terms of specific parameters (such as quantities, formulations, times and the like), that the presentation it is merely exemplary and illustrative of the process for purifying electrolyte and not limiting it.
[000149] In a first stage of the process to purify electrolyte, electrolyte 206 (in some embodiments, the ionic liquid) is mixed with deionized water and then raised to a moderate temperature for some period of time. In a proof of concept, fifty (50) milliliters (ml) of ionic liquid were mixed with eight hundred and fifty (850) milliliters (ml) of deionized water. The mixture was raised to a constant temperature of sixty (60) degrees Celsius for about twelve (12) hours and subjected to constant agitation (of about one hundred and twenty (120) revolutions per minute (rpm)).
[000150] In a second stage, the mixture of ionic liquid and deionized water is allowed to partition. In this example, the mixture was allowed to transfer through a funnel and set for about four (4) hours.
[000151] In a third stage, the ionic liquid is collected. In this example, a water phase of the mixture resided at the bottom, with an ionic liquid phase at the top. The ionic liquid phase was transferred to another beaker.
[000152] In a fourth step, a solvent was mixed with the ionic liquid. In this example, a volume of about twenty five (25) milliliters (ml) of ethyl acetate was mixed with the ionic liquid. The mixture was again raised to a moderate temperature and stirred for some time.
[000153] Although ethyl acetate was used as the solvent, the solvent can be at least one of diethyl ether, pentone, cyclopentone, hexane, cyclohexane, benzene, toluene, 1-4 dioxane, chloroform or any combination thereof other material (s) that exhibit appropriate performance characteristics. Some of the desired performance characteristics include those of a non-polar solvent as well as a high degree of volatility.
[000154] In a fifth stage, the carbon powder is added to the mixture of the ionic liquid and solvent. In this example, about twenty (20) weight percent (weight%) carbon (about a 0.45 micrometer diameter) was added to the mixture.
[000155] In a sixth stage, the ionic liquid is mixed again. In this example, the mixture with the carbon powder was then subjected to constant stirring (120 rpm) overnight at about seventy (70) degrees Celsius.
[000156] In a seventh stage, carbon and ethyl acetate are separated from the ionic liquid. In this example, the carbon was separated using Buchner filtration with a glass microfiber filter. Multiple filtrations (three) were performed. The collected ionic liquid was then passed through a 0.2 micrometer syringe filter to remove substantially all of the carbon particles. In this example, the solvent was then separated from the ionic liquid using rotary evaporation. Specifically, the ionic liquid sample was stirred while increasing the temperature from seventy (70) degrees Celsius to eighty (80) degrees Celsius and finished at one hundred (100) degrees Celsius. Evaporation was carried out for about fifteen (15) minutes at each of the respective temperatures.
[000157] The process to purify electrolyte has proved to be very effective. For the sample ionic liquid, the water content was measured by titration, with a titration instrument provided by Mettler-Toledo Inc., of Columbus, Ohio, USA (model No: AQC22). The halide content was measured with an ISE instrument provided by Hanna Instruments of Woonsocket, Rhode Island (model No. AQC22). The standard solution for the ISE instrument was obtained from Hanna and included HI 4007-03 (1,000 ppm standard chloride), HI 4010-03 (1,000 ppm standard fluoride) HI 4000-00 (ISA for halide electrodes) and HI 4010-00 (TISAB solution for fluoride electrode only). Before taking the measurements, the ISE instrument was calibrated with the standard solutions using 0.1, 10, 100 and 1,000 parts per million (ppm) of the standards, mixed with deionized water. The ISA buffer was added to the standard at a 1:50 ratio for the measurement of Cl- ions. The results are shown in Table 2. Table 2 Purification data for electrolyte

[000158] A four step process was used to measure the halide ions. First, Cl- and F- ions were measured in the deionized water. Then, a solution of 0.01 M of ionic liquid was prepared with deionized water. Subsequently, the Cl- and F- ions were measured in the solution. The estimation of the halide content was then determined by subtracting the amount of ions in the water from the amount of ions in the solution.
[000159] As an overview, a method of mounting a cylindrically shaped ultracapacitor 210 is provided. Starting with electrodes 203, each electrode 203 is manufactured since the energy storage medium 201 has been associated with current collector 202. A plurality of threads are then coupled to each electrode 203 at appropriate locations. A plurality of electrodes 203 is then oriented and assembled with an appropriate number of spacers 205 between them to form storage cell 212. Storage cell 212 can then be laminated to a cylinder and can be secured with a housing. In general, the respective fillets within the fillets are then grouped together to form each of the terminals 208.
[000160] Before the incorporation of electrolyte 206 into ultracapacitor 210 (as before assembly of storage cell 212, or later) each component of ultracapacitor 210 can be dried to remove hydration. This can be done with unmounted components (i.e., an empty housing 207, as well as each of the electrodes 203 and each of the separators 205) and subsequently with assembled components (such as the storage cell 212).
[000161] Drying can be carried out, for example, at an elevated temperature in a vacuum environment. Once drying has been carried out, storage cell 212 can then be packed in housing 207 without a seal or final termination. In some embodiments, packaging is carried out in an atmosphere with less than 50 parts per million (ppm) of water. The unfinished ultracapacitor 210 can then be dried again. For example, the unfinished ultracapacitor 210 can be vacuum dried over a temperature range of about 100 degrees Celsius to about 300 degrees Celsius. Once this final drying is complete, housing 207 can then be sealed, for example, in an atmosphere with less than 50 ppm hydration.
[000162] In some embodiments, once the drying process (which can also be referred to as the "baking" process) has been completed, the environment surrounding the components can be filled with an inert gas. Exemplary gases include argon, nitrogen, helium and other gases that exhibit similar properties (as well as combinations of them).
[000163] In general, a filling port (a hole in a surface of housing 207) is included in housing 207, or can be added later. Once the ultracapacitor 210 has been filled with electrolyte 206, the filling door can then be closed. The closing of the filling door can be completed, for example, by welding material (for example, a metal that is compatible with the housing 207) in or on the filling door. In some embodiments, the filling door can be closed temporarily before filling, so that the ultracapacitor 210 can be moved to another environment, for reopening, filling and subsequent closing. However, as discussed in this document, ultracapacitor 210 is considered to be dry and filled in the same environment.
[000164] Several methods can be used to fill housing 207 with a desired amount of electrolyte 206. In general, filling process control can provide, among other things, increases in capacitance, reductions in equivalent series resistance (ESR) and limitation of electrolyte waste 206. A vacuum filling method is provided as a non-limiting example of a technique for filling housing 207 and wetting storage cell 212 with electrolyte 206.
[000165] First, however, note that measures can be taken to ensure that any material that has the potential to contaminate components of the ultracapacitor 210 is clean, compatible and dry. As a matter of convention, "good hygiene" can be considered to ensure that assembly processes and components do not introduce contaminants into the ultracapacitor 210. In addition, as a matter of convention, a "contaminant" can be considered defined as any unwanted material that will adversely affect the performance of the ultracapacitor 210 if introduced. Also note that, in general, in this document, contaminants can be assessed as a concentration, as in parts per million (ppm). The concentration can be taken as weight, volume, sample weight, or any other form as determined appropriate.
[000166] In the "vacuum method" a container is placed in the housing 207 around the filling port. An amount of electrolyte 206 is then placed in the container in an environment that is substantially free of oxygen and water (i.e., hydration). A vacuum is then extracted into the environment, thus pulling any air out of the housing and then simultaneously extracting electrolyte 206 into housing 207. The surrounding environment can then be refilled with inert gas (such as argon, nitrogen, or similar, or some combination of inert gases), if desired. The ultracapacitor 210 can be checked to see if the desired amount of electrolyte 206 has been extracted inside. The process can be repeated as needed until the desired amount of electrolyte 206 is in ultracapacitor 210.
[000167] After filling with electrolyte 206, in some embodiments, the material can be fitted to the filling port to seal the ultracapacitor 210. The material can be, for example, a metal that is compatible with the 207 housing and the 206 electrolyte. In one example, the material is forcibly attached to the fill port, essentially "cold soldering" a plug to the fill port. Obviously, the force fitting can be complemented with other welding techniques as further discussed in this document.
[000168] In order to show how the filling process affects ultracapacitor 210, two similar modalities of ultracapacitor 210 were built. One was filled without vacuum, the other was filled under vacuum. The electrical performance of the two modalities is provided in Table 3. Through the repeated performance of these measurements, it was observed that the increased performance is achieved by filling the ultracapacitor 210 through the application of vacuum. It has been found that, in general, it is desired that the pressure within housing 207 be reduced to below about 150 mTorr and more particularly to below about 40 mTorr. Table 3 Comparative performance for filling methods

[000169] In order to evaluate the effectiveness of vacuum filling techniques, two different small shell cells were tested. The small shell cells included two electrodes 203, each electrode 203 being based on the carbonaceous material. Each of the electrodes 203 were placed opposite and facing each other. The separator 205 was arranged between them to avoid a short circuit and everything was embedded in 206 electrolyte. Two external flaps were used to provide four measurement points. The separator 205 used was a polyethylene separator 205 and the cell had a total volume of about 0.468 ml. This resulted in a substantial decrease in the initial leakage current, as well as a decrease in the leakage current through the last portion of the measurement interval.
[000170] The leakage current can be determined in several ways. Qualitatively, the leakage current can be considered as current drawn in a device, once the device has reached an equilibrium state. In practice, it is always or almost always necessary to estimate the actual leakage current as a steady state that can, in general, only be addressed asymptotically. Therefore, the leakage current in a given measurement can be approximated by measuring the current drawn in ultracapacitor 210, although ultracapacitor 210 is retained at a substantially fixed voltage and exposed to a substantially fixed ambient temperature for a relatively long period of time. In some cases, a relatively long period of time can be determined by approximating the current time function as an exponential function, then allowing several characteristic time constants to pass (for example, about 3 to 5). This duration often ranges from about 50 hours to about 100 hours for many ultracapacitor technologies. Alternatively, if this long period of time is impracticable for any reason, the leakage current can simply be extrapolated, again, perhaps, by approaching the current time function as an exponential or any approximation function considered appropriate. Notably, the leakage current will generally depend on the ambient temperature. Thus, in order to characterize the performance of a device at a temperature or a temperature range, it is, in general, important to expose the device to the ambient temperature of interest when measuring the leakage current.
[000171] Refer now to Figure 10, in which the aspects of an exemplary housing 207 are shown. Among other things, housing 207 provides the structure and physical protection for ultracapacitor 210. In this example, housing 207 includes a cylindrically shaped annular body 220 and a complementary termination 224. In this embodiment, termination 224 includes a central portion that has been removed and filled with an electrical insulator 226. A termination pass 219 penetrates through electrical insulator 226 to provide users with access to stored energy.
[000172] Common materials for housing 207 include stainless steel, aluminum, tantalum, titanium, nickel, copper, tin, various alloys, laminate and the like. Structural materials, such as some polymer-based materials, can be used in housing 207 (generally in combination with at least some metallic components).
[000173] Although this example represents only a passage 219 at termination 224, it should be recognized that the construction of housing 207 is not limited by the modalities discussed in this document. For example, termination 224 may include a plurality of passages 219. In some embodiments, body 220 includes a similar second termination 224 at an opposite end of the annular cylinder. In addition, it should be recognized that housing 207 is not limited to modalities that have a cylindrically shaped annular body 220. For example, housing 207 may be a shell design, a prismatic design, a small enclosure, or any other design that it is suitable for the needs of the designer, manufacturer or user.
[000174] In this example, termination 224 is manufactured with an outer diameter that is designed to fill tightly within an inner diameter of body 220. When assembled, termination 224 can be welded to body 220, then providing users with an airtight seal .
[000175] Referring now to Figure 11, an exemplary energy storage cell 212 is shown. In this example, energy storage cell 212 is a "jelly roll" type of energy storage. In these embodiments, the energy storage materials are laminated in tight packaging. A plurality of fillets generally form each terminal 208 and provide electrical access to the appropriate layer of the energy storage cell 212. In general, when assembled, each terminal 208 is electrically coupled to housing 207 (as with a respective passageway 219 and / or directly to accommodation 207). The energy storage cell 212 can take a variety of forms. There are, in general, at least two pluralities of threads (for example, terminals 208), one for each current collector 202. For simplicity, only one terminal 208 is shown in several embodiments illustrated in the present document.
[000176] A highly effective seal of housing 207 is desired. In other words, avoiding the intrusion of the external environment (such as air, humidity, etc., ...) helps to maintain the purity of the components of the energy storage cell 212. Additionally, this prevents the leakage of electrolyte 206 from the storage cell of 212 energy.
[000177] Referring now to Figure 12, housing 207 may include an inner barrier 230. In some embodiments, barrier 230 is a liner. In this example, barrier 230 is formed of polytetrafluoroethylene (PTFE). Polytetrafluoroethylene (PTFE) exhibits several properties that make this composition well suited for barrier 30. PTFE has a melting point of about 327 degrees Celsius, has excellent dielectric properties, has a coefficient of friction between about 0.05 to 0, 10, which is the third smallest of any known solid material, has high corrosion resistance and other beneficial properties. In general, an internal portion of termination 224 may include barrier 230 disposed thereon.
[000178] Other materials can be used for barrier 230. Among these other materials there are forms of ceramics (any type of ceramic that can be applied properly and meets the performance criteria), other polymers (preferably, a temperature polymer high) and the like. Other exemplary include polymers include perfluoroalkoxy (PFA) and fluorinated ethylene propylene (FEP) as well as ethylene tetrafluoroethylene (ETFE).
[000179] Barrier 230 can include any material or combinations of materials that provide reductions in electrochemical reactions or other types of reactions between the energy storage cell 212 and housing 207 or components of housing 207. In some embodiments, combinations are manifested as homogeneous dispersions of different materials within a single layer. In other embodiments, the combinations are manifested as different materials within a plurality of layers. Other combinations can be used. In short, barrier 230 can be considered as at least one of an electrical and chemically inert insulator (that is, one that exhibits low reactivity) and therefore substantially resists or prevents at least one among electrical and chemical interaction between the storage cell. 212 and accommodation 207. In some embodiments, the terms "low reactivity" and "low chemical reactivity" refer, in general, to a rate of chemical interaction that is below a level of concern for interested third parties.
[000180] In general, the interior of housing 207 can be host to barrier 230 so that all surfaces of housing 207 that are exposed to the interior are covered. At least one untreated area 231 can be included within body 220 and an outer surface 236 of termination 224 (see Figure 13A). In some embodiments, the untreated area 231 (see Figure 13B) can be included to take into account assembly requirements, such as areas that will be sealed or connected (as by welding).
[000181] Barrier 230 can be applied to internal portions using conventional techniques. For example, in the case of PTFE, barrier 230 can be applied by painting or spraying barrier 230 on the internal surface as a coating. A mask can be used as part of the process to ensure that untreated areas 231 retain the desired integrity. In short, a variety of techniques can be used to provide barrier 230.
[000182] In an exemplary embodiment, barrier 230 is about 3,000 to about 5,000 thick, although the material used for barrier 230 is a PFA-based material. In this example, the surfaces for receiving the material that make up the barrier 230 are prepared with abrasive blasting, such as with aluminum oxide. Once the surfaces are cleaned, the material is applied, first as a liquid and then as a powder. The material is cured by a heat treatment process. In some embodiments, the heating cycle is about 10 minutes to about 15 minutes long, at temperatures of about 370 degrees Celsius. This results in a continuous finish for barrier 230 that is substantially free from pinhole size defects or smaller. Figure 14 represents the assembly of an embodiment of the ultracapacitor 210 in accordance with the teachings in this document. In this embodiment, the ultracapacitor 210 includes the body 220 which includes the barrier 230 disposed therein, a termination 224 with the barrier 230 disposed therein and the energy storage cell 212. During assembly, the termination 224 is adjusted on the body 220. A first of terminals 208 is electrically coupled to termination passage 219, while a second of terminals 208 is electrically coupled to housing 207, typically at the bottom, side or termination 224. In some embodiments, the second of terminals 208 is coupled to another passage 219 (as from an opposite termination 224).
[000183] With the barrier 230 disposed on the internal surface (s) of the housing 207, an electrochemical reaction and others between the housing 207 and the electrolyte are greatly reduced or substantially eliminated. This is particularly significant at higher temperatures where a rate of chemical reaction and other reactions is generally increased.
[000184] Referring now to Figure 15, the relative performance of ultracapacitor 210 in comparison to an otherwise equivalent ultracapacitor is shown. In Figure 15A, the leakage current is shown for a prior art modality of ultracapacitor 210. In Figure 15B, the leakage current is shown for an equivalent ultracapacitor 210 that includes barrier 230. In Figure 15B, ultracapacitor 210 is electrically equivalent to the ultracapacitor whose leakage current is shown in Figure 15A. In both cases, housing 207 was stainless steel and the voltage supplied to the cell was 1.75 Volts and the electrolyte was not purified. The temperature was held constant at 150 degrees Celsius. Notably, the leakage current in Figure 15B indicates a comparatively lower starting value and no substantial increase over time while the leakage current in Figure 15A indicates a comparatively higher initial value as well as a substantial increase over time.
[000185] In general, barrier 230 provides an adequate thickness of suitable materials between the energy storage cell 212 and housing 207. Barrier 230 may include a homogeneous mixture, a heterogeneous mixture and / or at least one layer of materials . Barrier 230 can provide complete coverage (ie, provide coverage over the inner surface area of the housing with the exception of electrode contacts) or partial coverage. In some embodiments, barrier 230 is formed of multiple components. Consider, for example, the modality shown below and illustrated in Figure 16.
[000186] Referring to Figure 16, aspects of an additional modality are shown. In some embodiments, the energy storage cell 212 is deposited within an envelope 233. That is, the energy storage cell 212 has the barrier 230 arranged over it, rolled over it, or otherwise applied to separate the energy storage cell 212 of housing 207 once assembled. The envelope 233 can be applied well before the packaging of the energy storage cell 212 in the housing 207. Therefore, the use of an envelope 233 can present certain advantages, as for the manufacturers. (Note that envelope 233 is shown as loosely arranged over energy storage cell 212 for purposes of illustration).
[000187] In some embodiments, envelope 233 is used in conjunction with the liner, in which the liner is arranged on at least a portion of the internal surfaces. For example, in one embodiment, the liner is disposed within the interior of housing 207 only in an area where envelope 233 can be at least partially compromised (such as a projection terminal 208). Together, the envelope 233 and the liner form an effective barrier 230.
[000188] Consequently, the incorporation of barrier 230 can provide an ultracapacitor that exhibits leakage current with comparatively low initial values and substantially slower increases in leakage current over time in view of the prior art. Significantly, the leakage current of the ultracapacitor remains at practical levels (ie desirably low) when the ultracapacitor is exposed to ambient temperatures to which prior art capacitors would exhibit prohibitively large leakage current values and / or prohibitively rapid increases. leakage current over time.
[000189] As a matter of convention, the term "leakage current" refers, in general, to a current drawn by the capacitor that is measured after a given period of time. This measurement is performed when the capacitor terminals are maintained at a substantially fixed potential difference (terminal voltage). When assessing the leakage current, the typical time period is seventy-two (72) hours, although different periods may be used. It is observed that leakage current for the prior art capacitors increases, in general, with increasing volume and surface area of the energy storage medium and the attendant increase in the internal surface area of the housing. In general, an increasing leakage current is considered to be indicative of progressively increasing reaction rates within the ultracapacitor 210. The performance requirements for the leakage current are, in general, defined by the environmental conditions prevalent in a particular application. For example, for an ultracapacitor 210 that has a volume of 20 ml, a practical limit on the leakage current can drop below 100 mA.
[000190] Having then described the modalities of barrier 230 and various aspects of it, it should be recognized that ultracapacitor 210 may exhibit other benefits as a result of reduced reaction between housing 207 and energy storage medium 201. For example, an effective series resistance (ESR) of the ultracapacitor 210 may exhibit comparatively lower values over time. In addition, unwanted chemical reactions that take place in a prior art capacitor often create unwanted effects such as gas outflow, or in the case of airtight housing, housing expansion. In both cases, these fillets compromise the structural integrity of the housing and / or the hermetic seal of the capacitor. Finally, this can lead to leaks or catastrophic failure of the prior art capacitor. In some embodiments, these effects can be substantially reduced or eliminated by applying a revealed barrier 230.
[000191] It should be recognized that the terms "barrier" and "coating" are not limiting the teachings in this document. That is, any technique for applying the appropriate material to the interior of housing 207, body 220 and / or termination 224 can be used. For example, in other embodiments, barrier 230 is actually manufactured inside or on the material that makes up the body housing 220, the material then being worked or shaped as appropriate to form the various components of housing 207. When considering some of the many possible techniques for applying barrier 230, it may be equally appropriate to roll, bombard, sinter, laminate, print, or otherwise apply the material (s). In summary, barrier 230 can be applied using any technique considered appropriate by a manufacturer, designer and / or user.
[000192] The materials used in barrier 230 can be selected according to properties such as reactivity, dielectric value, melting point, adhesion to materials in housing 207, friction coefficient, cost and other similar factors. Combinations of materials (such as layered, mixed, or otherwise combined) can be used to provide desired properties.
[000193] The use of an accentuated housing 207, such as one with barrier 230, may, in some embodiments, limit the degradation of electrolyte 206. Although barrier 230 has a technique for providing an accentuated housing 207, other techniques can be used . For example, the use of a 207 housing made of aluminum would be advantageous, due to the electrochemical properties of aluminum in the presence of 206 electrolyte. However, given the difficulties in manufacturing aluminum, it was not possible (until now) to build the housing modalities 207 that take advantage of aluminum.
[000194] Additional modalities of housing 207 include those that present aluminum to all internal surfaces, which can be exposed to the electrolyte, although it does provide users with an ability to weld and hermetically seal the housing. The enhanced performance of the ultracapacitor 210 can be realized through reduced internal corrosion, elimination of problems associated with the use of non-similar metals in a conductive medium and for other reasons. Advantageously, the housing 7 uses existing technology, these available electrode inserts that include glass-to-metal seals (and may include those made of stainless steel, tantalum or other advantageous materials and components) and therefore are economically manufactured.
[000195] Although the modalities of housing 207 that are suitable for ultracapacitor 10 are disclosed in this document, these modalities (as in the case with barrier 230) can be used with any type of energy storage considered appropriate and can include any type of workable technology. For example, other forms of energy storage can be used, including electrochemical batteries, in particular, lithium-based batteries.
[000196] In some embodiments, a material used for the construction of the body 220 includes aluminum, which may include any type of aluminum or aluminum alloy considered appropriate by a designer or manufacturer (all of which are generally referred to in this document simply as "aluminum"). Various alloys, laminates and the like can be placed on (for example, coated with) aluminum (aluminum being exposed to an interior of the body 220). Additional materials (such as structural materials or electrically insulating materials, such as some polymer-based materials) can be used to complement the body and / or the housing 207. Materials placed on aluminum can likewise be chosen for what is considered appropriate by a designer or manufacturer.
[000197] In general, the material (s) exposed to an interior of housing 207 exhibits suitably low reactivity when exposed to electrolyte 206 and, therefore, are merely illustrated in some of the modalities and are not limiting the teachings in this document.
[000198] Although this example represents only a passage 219 at termination 224, it should be recognized that the construction of housing 207 is not limited by the modalities discussed in this document. For example, termination 224 may include a plurality of passages 219. In some embodiments, body 220 includes a similar second termination 224 at the opposite end of the annular cylinder. Additionally, it should be recognized that housing 207 is not limited to modalities that have a cylindrically shaped annular body 220. For example, housing 207 can be a hull design, a prismatic design, a pocket, or any other design that is appropriate to the needs of the designer, manufacturer or user.
[000199] A highly effective seal of housing 207 is desired. That is, preventing the intrusion of the external environment (such as air, humidity, etc., ...) helps to maintain the purity of the components of the energy storage cell 212. Additionally, this prevents the leakage of electrolyte 206 from the storage cell of 212 energy.
[000200] Referring now to Figure 17, modalities aspects of a raw block 234 for termination 224 are shown. In Figure 17A, the crude block 234 includes a multilayer material. A layer of a first material 241 is aluminum. A layer of a second material 242 is stainless steel. In the modalities of Figure 17, stainless steel is plated into aluminum, thus providing a material that exhibits a desired combination of metallurgical properties. That is, modalities provided in this document, aluminum is exposed to an interior of the energy storage cell (ie, the housing), although stainless steel is exposed to the exterior. In this way, the advantageous electrical properties of aluminum are appreciated, although it depends on the structural properties (and metallurgical properties, that is, weldability) of stainless steel for construction. The multilayer material may include additional layers as deemed appropriate.
[000201] As mentioned above, the layer of the first material 241 is coated (or with) the layer of the second material 242. As used herein, the terms "plated," "plated" and the like refer to the bonding of different metals . Plating is often achieved by extruding two metals through a mold as well as gripping or laminating the sheets together under high pressure. Another process, such as laser plating, can be used. One result is a sheet of material composed of multiple layers, in which the multiple layers of material are joined together so that the material can be worked as a single sheet (for example, formed as a single sheet of homogeneous material would be formed).
[000202] Referring further to Figure 17A, in one embodiment, a flat piece sheet (as shown) is used to provide the blank 234 to create a flat end 224. A portion of the second material layer 242 can be removed (as around a circumference of the termination 224) in order to facilitate the attachment of the termination 224 to the body 220. In Figure 17B, another embodiment of the raw block 234 is shown. In this example, raw block 234 is supplied as a sheet of plated material that is formed in a concave configuration. In Figure 17C, the raw block 234 is provided as a sheet of plated material that is formed in a convex configuration. The termination 224 which is manufactured from the various modalities of the raw block 234 (such as those shown in Figure 17), are configured to support welding to body 220 of housing 207. More specifically, the embodiment of Figure 17B is adapted to fit within of an internal diameter of the body 220, although the embodiment of Figure 17C is adapted to fit over an external diameter of the body 220. In several alternative embodiments, the layers of plated material within the sheet can be inverted.
[000203] When assembled, termination 224 can be welded to body 220, thus providing users with an airtight seal. Exemplary welding techniques include laser welding and TIG welding and may include other forms of welding as deemed appropriate.
[000204] Referring now to Figure 18, an embodiment of an electrode assembly 250 is shown. The electrode assembly 250 is designed to be installed in the raw block 234 and to provide electrical communication of the energy storage medium to a user . In general, the electrode assembly 250 includes a sleeve 251. The sleeve 251 surrounds the insulator 226, which in turn surrounds the passage 219. In this example, the sleeve 251 is an annular cylinder with a flanged top portion.
[000205] In order to assemble the termination 224, a perforation (not shown) is made in the raw block 234. The perforation has a geometry that is sized to correspond to the electrode assembly 250. Consequently, the electrode assembly 250 is inserted in the drilling of the raw block 234. Once the electrode assembly 250 is inserted, the electrode assembly 250 can be attached to the raw block 234 using a technique such as welding. The welding can be laser welding that welds about a circumference of the flange of sleeve 251. Referring to Figure 29, the points 261 at which the welding is performed are shown. In this embodiment, points 261 provide suitable locations for welding stainless steel to stainless steel, a relatively simple welding procedure. Consequently, the teachings in this document provide for welding the electrode assembly 250 securely in place in the raw block 234.
[000206] The material for constructing sleeve 251 can include various types of metals or metal alloys. In general, materials for sleeve 251 are selected according to, for example, structural integrity and bonding capacity (to crude block 234). Exemplary materials for sleeve 251 include stainless steel 304 or stainless steel 316. The material for constructing passageway 219 can include various types of metals or metal alloys. In general, the materials for passage 219 are selected according to, for example, structural integrity and electrical conductance. Exemplary materials for the electrode include 446 stainless steel or 52 alloy.
[000207] In general, the insulator 226 is connected to the sleeve 251 and the passage 219 by known techniques (i.e., glass to metal bonding). The material for building insulator 226 may include, without limitation, various types of glass, including glass, ceramic glass or high temperature ceramic materials. In general, the materials for the insulator are selected according to, for example, structural integrity and electrical resistance (ie, electrical insulation properties).
[000208] The use of components (such as the previous modality of the 250 electrode assembly) that depends on the connection of glass to metal as well as the use of various welding techniques provides the hermetic seal of the energy storage. Other components can be used to also provide airtight seal. As used herein, the term "hermetic seal" refers, in general, to a seal that exhibits a leakage rate not greater than that defined in this document. However, it is considered that the actual sealing effectiveness may work better than this standard.
[000209] Additional techniques or other techniques for coupling the electrode assembly 250 to the raw block 234 include the use of a bonding agent under the flange of the sleeve 251 (between the flange and the layer of second material 242), when these techniques deemed appropriate.
[000210] Referring now to Figure 20, the energy storage cell 212 is arranged inside the body 220. The at least one terminal 208 is properly coupled (as in passage 219) and the termination 224 is matched to the body 220 for supply the ultracapacitor 210.
[000211] Once assembled, termination 224 and body 220 can be sealed. Figure 21 represents several modalities of assembled energy storage (in this case, the ultracapacitor 210). In Figure 21A, a flat crude block 234 (see Figure 17A) is used to create a flat termination 224. Once termination 224 is fitted to body 220, termination 224 and body 220 are welded to create a seal 262 In this case, as body 220 is an annular cylinder, the weld proceeds circumferentially around body 220 and termination 224 to provide seal 262. In a second embodiment, shown in Figure 21B, the concave rough block 234 (see Figure 17B) is used to create a concave termination 224. Once termination 224 is fitted to body 220, termination 224 and body 220 are welded to create seal 262. In a third embodiment, shown in Figure 21C, the convex crude block 234 (see Figure 17C) is used to create a convex termination 224. Once termination 224 is fitted to body 220, termination 224 and body 220 can be welded to create seal 262.
[000212] As appropriate, the plated material can be removed (by techniques such as, for example, machining or etching, etc., ...) to expose the other metal in the multilayer material. Consequently, in some embodiments, seal 62 may include an aluminum-to-aluminum weld. The aluminum-to-aluminum weld can be supplemented with other fasteners, as appropriate.
[000213] Other techniques can be used to seal housing 207. For example, laser welding, TIG welding, resistance welding, ultrasonic welding and other forms of mechanical sealing can be used. It should be noted, however, that in general, traditional forms of mechanical sealing alone are not suitable for providing the robust hermetic seal offered in the ultracapacitor 210.
[000214] In some embodiments, the multilayer material is used for the internal components. For example, aluminum can be plated with stainless steel to provide a multilayer material on at least one of the 208 terminals. In some of these embodiments, a portion of the aluminum can be removed to expose stainless steel. The exposed stainless steel can then be used to secure terminal 208 to passage 219 using simple welding procedures.
[000215] The use of plated material for internal components may require particular types of plated material. For example, it may be beneficial to use plated material that includes aluminum (bottom layer), stainless steel and / or tantalum (middle layer) and aluminum (top layer), which then limits the exposure of stainless steel to the internal environment of the ultracapacitor 210. These modalities can be improved by, for example, additional coating with polymeric materials, such as PTFE.
[000216] In general, mounting the housing often involves placing the storage cell 212 inside the body 220 and filling the body 220 with the electrolyte 206. A drying process can be carried out. Exemplary drying which includes heating body 220 with storage cell 212 and electrolyte 206 in it, often under reduced pressure (e.g., a vacuum). Once proper drying (optional) has been carried out, the final assembly steps can be carried out. In the final stages, internal electrical connections are made, termination 224 is installed and termination 224 is hermetically sealed to body 220, for example, by terminating termination 224 to body 220.
[000217] Consequently, the provision of a housing 207 that takes advantage of the multilayered material provides an energy storage that exhibits leakage current with comparatively low initial values and substantially slower increases in leakage current over time in view of the prior art. Significantly, the leakage current from the energy storage remains at practical (ie desirably low) levels when ultracapacitor 210 is exposed to ambient temperatures for which prior art capacitors would exhibit prohibitively high leakage current and / or prohibitively high increases in leakage current over time.
[000218] Additionally, ultracapacitor 210 may exhibit other benefits as a result of reduced reaction between housing 207 and energy storage cell 212. For example, an effective series resistance (ESR) of energy storage may exhibit comparatively lower values over time. In addition, the unwanted chemical reactions that take place in a prior art capacitor often create unwanted effects such as gas outflow, or in the case of a hermetically sealed housing, expansion of the 207 housing. In both cases, this leads to a compromise in structural integrity of housing 207 and / or airtight sealing of energy storage. Finally, this lead to leaks or catastrophic failure of the prior art capacitor. These effects can be substantially reduced or eliminated by applying a revealed barrier.
[000219] Consequently, users are now provided with a housing 207 for energy storage, wherein a substantial portion up to all internal surfaces of housing 207 are aluminum (and may include a material without interference, as described below). Therefore, internal corrosion problems are avoided and designers are offered greater flexibility in selecting appropriate materials for the 206 electrolyte.
[000220] Through the use of a multilayer material (for example, a plated material), stainless steel can be incorporated into housing 207 and therefore components with glass to metal seals can be used. Components can be welded to the stainless steel side of the plated material using techniques such as laser or resistance welding, while the aluminum side of the plated material can be welded to other aluminum parts (eg body 220) .
[000221] In some embodiments, an insulating polymer can be used to coat parts of housing 207. In this way, it is possible to guarantee that the components of the energy storage are only exposed to acceptable types of metal (such as aluminum). The exemplary insulating polymer includes PFA, FEP, TFE and PTFE. Suitable polymers (or other materials) are limited by the needs of a system designer or manufacturer and the properties of the respective materials. Reference can be made to Figure 22, in which a small amount of insulating material 239 is included to limit the exposure of electrolyte 206 to the stainless steel of sleeve 251 and port 219. In this example, terminal 208 is coupled to port 219, as by welding and then coated with insulating material 239.
[000222] Refer now to Figure 23 in which the assembly aspects of another modality of termination 224 are represented. Figure 23A represents a model (i.e., raw block 234) that is used to provide a termination body 224. The model is, in general, sized to match housing 207 of an appropriate type of energy storage cell ( such as the ultracapacitor 210). The termination 224 can be formed by initially providing the model that forms the model, which includes a dome 237 within the model (shown in Figure 23B) and then perforating dome 237 to provide a passage 232 (shown in Figure 23C) . Obviously, the raw block 234 (e.g., a die ring) can be pressed or otherwise manufactured so that the foregoing features are provided simultaneously.
[000223] In general and in relation to these modalities, the termination may be formed of aluminum, or an alloy thereof. However, the termination can be formed from any material that is considered suitable by a manufacturer, user, designer and the like. For example, termination 224 may be made from steel and passivated (i.e., coated with an inert coating) or otherwise prepared for use in housing 207.
[000224] Referring now to Figure 24, another embodiment of the electrode assembly 250 is shown. In these embodiments, the electrode assembly 250 includes the passage 219 and a hemispherically shaped material disposed over the passage 219. The hemispherically shaped material serves as insulator 226 and is generally shaped to conform to dome 237. Hemispherical insulator 226 can be manufactured from any material suitable to provide an airtight seal while withstanding the chemical influence of electrolyte 206. Exemplary materials include PFA (perfluoroalkoxy polymer), FEP (fluorinated ethylene-propylene), PVF (polyvinylfluoride), TFE (tetrafluoroethylene), CTFE (chlorotrifluoroethylene), PCTFE (polychloro-trifluoroethylene), ETFE (polyethylene-tetrafluoroethylene), ECTFE (polyethylene-ethoxy-trifluoroethylene) fluoropolymer like any other material that can exhibit similar properties (to different degrees s) and provide satisfactory performance (as exhibiting, among other things, high resistance to solvents, acids and bases at high temperatures, low cost and the like).
[000225] Passage 219 may be formed of aluminum, or an alloy thereof. However, passage 219 can be formed from any material that is considered suitable by a manufacturer, user, designer and the like. For example, passageway 219 can be made from steel and passivated (ie coated with an inert coating, such as silicon) or otherwise prepared for use in electrode 250 assembly. An exemplary passivation technique includes depositing a coating hydrogenated amorphous silicon on the substrate surface and functionalizing the coated substrate by exposing the substrate to a binding reagent that has at least one unsaturated hydrocarbon group under pressure and elevated temperature for an effective length of time. The hydrogenated amorphous silicon coating is deposited by exposing the substrate to silicon hydride gas under pressure and elevated temperature for an effective length of time.
[000226] Hemispheric insulation 226 can be dimensioned in relation to dome 237 so that a comfortable fit (that is, airtight seal) is achieved when assembled at termination 224. Hemispheric insulation 226 does not have to be perfectly symmetrical or proportional hemispheric proportions . That is, the hemispherical insulator 226 is substantially hemispherical and may include, for example, high adjustments in proportions, a modest flange (as at the base) and other features as deemed appropriate. Hemispheric insulation 226 is generally made of homogeneous material, however, this is not a requirement. For example, hemispherical insulator 226 may include a log filled with gas or air (not shown) in it for desired compressibility or expansion.
[000227] As shown in Figure 25, the electrode assembly 250 can be inserted into the model (i.e., the formed block 234) to provide a termination modality 224 that includes a hemispherical hermetic seal.
[000228] As shown in Figure 26, in various embodiments, retainer 243 can be attached or otherwise corresponded to a bottom of termination 224 (i.e., a portion of termination 224 that faces an interior of housing 207 and faces for energy storage cell 212). Retainer 243 can be connected to termination 224 using various techniques, such as aluminum welding (such as laser, ultrasonic and the like). Other techniques can be used for bonding, which includes, for example, stamping (i.e., mechanical bonding) and brazing. The connection can take place, for example, along a perimeter of the retainer 243. In general, the connection is provided at at least one connection point to create a desired seal 271. At least one fastener, such as a plurality of rivets can be used to seal insulator 226 inside retainer 243.
[000229] In the example in Figure 26, termination 224 is one of a concave design (see Figure 17B). However, other designs can be used. For example, a convex termination 224 can be provided (Figure 17C) and an over-termination 224 can also be used (a variation of the modality of Figure 17C, which is configured to mount as shown in Figure 21C).
[000230] In some embodiments, at least one of the housing 207 and the termination 224 includes materials that include a plurality of layers. For example, a first layer of material may include aluminum, with a second layer of material each being stainless steel. In this example, stainless steel is plated into aluminum, then providing a material that exhibits a desired combination of metallurgical properties. That is, in the modalities provided in this document, aluminum is exposed to an interior of the energy storage cell (that is, the housing), although stainless steel is exposed to the exterior. In this way, the advantageous electrical properties of aluminum are appreciated, while depending on the structural properties (and metallurgical properties, that is, weldability) of stainless steel for construction. The multilayer material may include additional layers as deemed appropriate. This advantageously provides stainless steel welding to stainless steel, a relatively simple welding procedure.
[000231] The material used for the termination as well as the passage 219 can be selected in relation to the thermal expansion of the hemispheric insulator 226. Additionally, the manufacturing techniques can also be planned to take into account the thermal expansion. For example, when fitting termination 224, a manufacturer may apply pressure to hemispherical insulation 226, thereby compressing at least somehow hemispheric insulation 226. In this way, at least some thermal expansion of termination 224 is provided without impairing effectiveness of the hermetic seal.
[000232] Although the material used for the construction of the body 220 includes aluminum, any type of aluminum or aluminum alloy considered appropriate by a designer or manufacturer (all of which are widely referred to in this document simply as "aluminum"). Various alloys, laminates and the like can be placed on (for example, plated) aluminum (the aluminum being exposed to an interior of the body 220. Additional materials (such as structural materials or electrically insulating materials, such as some materials based on polymer) can be used to complement the body and / or the housing 207. The materials disposed on the aluminum can likewise be chosen by what is considered appropriate by a designer or manufacturer.
[000233] The use of aluminum is not necessary or required. In short, material selection can provide the use of any material deemed appropriate by a designer, manufacturer, or user and the like. Considerations can be given to several factors, such as, for example, reduction of chemical electro-interaction with electrolyte 206, structural properties, cost and the like.
[000234] The storage cell 212 is now discussed in more detail. Refer to Figure 27, in which a cut-away view of the ultracapacitor 210 is provided. In this example, storage cell 212 is inserted into and contained within body 220. Each plurality of fillets is grouped together and attached to housing 207 as one of terminals 208. In some embodiments, the plurality of fillets is attached to a bottom of the body 220 (inside), then making body 220 a negative contact 255. Likewise, another plurality of fillets is grouped and coupled to passage 219, to provide a positive contact 256. The electrical insulation of negative contact 255 and the positive contact 256 is preserved by the electrical insulator 226. In general, the coupling of the fillets is carried out through welding, as at least one among laser and ultrasonic welding. Obviously, other techniques can be used as deemed appropriate.
[000235] It should be recognized that robust assembly techniques are required to provide highly effective energy storage. Consequently, some of the techniques for assembly are now discussed.
[000236] Referring now to Figure 28, the components of an exemplary 203 electrode are shown. In this example, electrode 203 will be used as negative electrode 203 (however, this designation is arbitrary and for reference only).
[000237] As can be seen from the illustration, at least in this modality, the separator 205 is, in general, of a longer length and wider width than the energy storage medium 201 (and the current collector 202 ). Using a larger separator 205, protection is provided against short circuit of negative electrode 203 with positive electrode 203. The use of additional material in separator 205 also provides better electrical protection for the fillets and terminal 208.
[000238] Refer now to Figure 29 which provides a side view of a storage cell embodiment 212. In this example, a layered stack of energy storage medium 201 includes a first separator 205 and a second separator 205, of so that electrodes 203 are electrically separated when storage cell 212 is mounted on a laminated storage cell 223. Note that the term "positive" and "negative" in relation to electrode 203 and mounting of ultracapacitor 210 is merely arbitrary and does reference to functionality when configured in ultracapacitor 210 and the load is stored therein. This convention, which was commonly adopted in the art, is not intended to apply that the charge is stored prior to assembly, or to connote any other aspect besides providing the physical identification of different electrodes.
[000239] Before the winding of the storage cell 212, the negative electrode 203 and positive electrode 203 are aligned in relation to each other. The alignment of the electrodes 203 generates a better performance of the ultracapacitor 210 according to a path length for ionic transport is, in general, minimized when there is a high degree of alignment. In addition, by providing a high degree of alignment, excess separator 205 is not included and the effectiveness of ultracapacitor 210 does not suffer as a result.
[000240] Referring now to Figure 30, a modality of storage cell 212 is shown in which electrodes 203 were laminated to laminated storage cell 223. One of the separators 205 is present as a layer of the outermost storage cell 212 and separates the energy storage means 201 from an interior of the housing 207.
[000241] "Polarity match" can be used to match a polarity of the outermost electrode in the laminated storage cell 223 with a polarity of the body 220. For example, in some embodiments, the negative electrode 203 is on the outermost side of the tightly packed packaging that provides the laminated storage cell 223. In these embodiments, another degree of guarantee against short circuit is provided. That is, where the negative electrode 203 is coupled to the body 220, the negative electrode 203 is placed as the outermost electrode in the laminated storage cell 223. Consequently, if the separator 205 fails, as by mechanical wear induced by the vibration of the ultracapacitor 210 during use, the ultracapacitor 210 will not fail as a result of a short circuit between the outermost electrode in the laminated storage cell 223 and the body 220.
[000242] For each modality of the laminated storage cell 223, a reference mark 272 can be at least on the separator 205. Reference mark 272 will be used to supply and locate the fillets on each of the electrodes 203. In some embodiments, the location of the fillets is provided by the calculation. For example, taking into account an internal diameter of the jelly roll and an overall thickness for the combined separators 205 and electrodes 203, a location for the placement of each of the fillets can be estimated. However, practice has shown that it is more effective and efficient to use a reference mark 272. Reference mark 272 may include, for example, a slit in one edge of the 205 separator (s).
[000243] In general, the reference mark 272 is used for each new specification of storage cell 212. That is, since a new specification of storage cell 212 may request a different thickness of at least one layer in it (on an earlier modality), the use of the earlier reference marks may be at least somewhat inaccurate.
[000244] In general, the reference mark 272 is manifested as a single radial line that crosses the lamination from a center of the same to a periphery of the same. Consequently, when the fillets are installed along the reference mark 272, each fillet will align with the remaining fillets (as shown in Figure 32). However, when the storage cell 212 is unwound (for the modalities in which the storage cell 212 is or will roll a roll), the reference mark 272 can be considered to be a plurality of markings (as shown in Figure 31). As a matter of convention, regardless of the modality or appearance of the marking of the storage cell 212, identification of a location for incorporating the fillet is considered to involve the determination of a "reference mark 272" or a "set of reference marks 272. "
[000245] Referring now to Figure 31, once the reference mark 272 has been established (as marking a laminated storage cell 212), an installation site for each of the fillets is provided (ie, described reference mark 272). Once each installation site has been identified, for each given construction specification of storage cell 212, the relative location of each installation site can be repeated for additional cases of the particular construction of storage cell 212.
[000246] In general, each fillet is coupled to a respective current collector 202 in storage cell 212. In some embodiments, both the current collector 202 and the fillet are manufactured from aluminum. In general, the fillet is coupled to the current collector 202 across the width, W, however, the fillet can be coupled by only a portion of the width, W. The coupling can be carried out, for example, ultrasonic welding of the fillet to the collector. chain 202. In order to perform the coupling, at least some of the energy storage means 201 can be removed (as appropriate) so that each thread can be properly attached to the chain collector 202. Other preparations and accommodations can be made , as deemed appropriate, to provide the coupling.
[000247] Obviously, opposite reference marks 273 can be included. That is, in the same way that reference marks 272 are provided, a set of opposite reference marks 273 can be made to take into account the installation of fillets for the opposite polarity. That is, reference marks 272 can be used to install fillets to a first electrode 203, such as negative electrode 203, while opposite reference marks 273 can be used to install fillets to positive electrode 203. In the mode in which the cell laminated storage device 223 is cylindrical, the opposing reference marks 273 are arranged on an opposite side of the energy storage means 201 and offset by length of the reference marks 272 (as shown).
[000248] Note that in Figure 31, the reference marks 272 and the opposite reference marks 273 are both shown to be arranged on a single electrode 203. That is, Figure 31 represents a modality that is merely for illustration of the spatial relationship (ie, linear) of the reference marks 272 and the opposite reference marks 273. This is not intended to imply that the positive electrode 203 and negative electrode 203 share the energy storage medium 201. However, it should be noted that in cases where the reference marks 272 and the opposite reference marks 273 are placed by rolling the storage cell 212 and then marking the separator 205, that the reference marks 272 and the opposite reference marks 273 can actually be provided in a single separator 205. However, in practice, only a set of the reference marks 272 and the opposite reference marks 273 would be used to install the fillets for any purpose. uer given electrode 203. That is, it should be recognized that the modality represented in Figure 31 must be complemented with another layer of the energy storage medium 201 for another electrode 203 that will be of an opposite polarity.
[000249] As shown in Figure 32, the antecedent assembly technique results in a storage cell 212 that includes at least one set of aligned threads. A first set of aligned fillets 291 is particularly useful when coupling storage cell 212 in its form as a laminated storage cell 223 to one of negative contact 255 and positive contact 256, while a set of opposite aligned fillets 292 provide coupling the energy storage medium 201 to an opposite contact (255, 256).
[000250] The laminated storage cell 223 can be surrounded by an enclosure 293. The enclosure 293 can be realized in a variety of embodiments. For example, the 293 wrapper can be supplied as KAPTONTM tape (which is a polyimide film developed by DuPont of Wilmington DE), or PTFE tape. In this example, the KAPTONTM tape encircles and adheres to the laminated storage cell 223. The wrapper 293 can be supplied without adhesive, such as a tight-fitting wrapper 293 that is slid into the laminated storage cell 223. The wrapper 293 can be more manifested as a pouch, as one that generally comprises laminated storage cell 223 (for example, as envelope 273 discussed above). In some of these embodiments, the casing 293 may include a material that functions as a functional shrink wrapper and thereby provides an efficient physical (and in some embodiments, chemical) closure of the laminated storage cell 223. In general, the casing 293 is formed of a material that does not interfere with the electrochemical functions of the ultracapacitor 210. The casing 293 can also provide partial coverage as needed, for example, to assist insertion of the laminated storage cell 223.
[000251] In some embodiments, the negative fillets and the positive fillets are located on opposite sides of the laminated storage cell 223 (in the case of a laminated storage cell of the jelly-roll type 223, the fillets for the negative polarity and the fillets for positive polarity they can be diametrically opposed). In general, placing the fillets for negative polarity and fillets for positive polarity on opposite sides of laminated storage cell 223 is performed to facilitate construction of laminated storage cell 223 as well as to provide improved electrical separation.
[000252] In some embodiments, once the aligned threads 291, 292 are assembled, each of the plurality of aligned threads 291, 292 is grouped together (in place) so that a shrink wrap (not shown) can be arranged around the plurality of aligned fillets 291, 292. In general, the shrink wrap is formed of PTFE, however, any compatible material can be used.
[000253] In some embodiments, once the heat shrinkable packaging material has been placed on the aligned fillets 291, the aligned fillets 291 are folded into a shape to be assumed when the ultracapacitor 210 has been assembled. That is, with reference to Figure 33, it can be seen that the aligned fillets assume a "Z" shape. After imparting a "Z-fold" to the aligned fillets 291, 292 and applying the heat shrink wrap, the heat shrink wrap can be heated or otherwise activated so that the heat shrink wrap retracts into place over the aligned fillets 291, 292. Consequently, in in some embodiments, the inline fillets 291, 292 can be strengthened and protected by a wrapper. The use of the Z-fold is particularly useful when coupling the energy storage means 201 to the passage 219 disposed within the termination 224.
[000254] Obviously, other modalities for coupling each set of aligned fillets 291, 292 (that is, each terminal 208) to a respective contact 255, 256 can be practiced. For example, in one embodiment, an intermediate thread is coupled to one of the passage 219 and the housing 207, so that coupling with a respective set of aligned threads 291, 292 is facilitated.
[000255] The materials used can be selected according to properties such as reactivity, dielectric value, melting point, adhesion to other materials, weldability, friction coefficient, cost and other similar factors. Combinations of materials (such as layered, mixed, or otherwise combined) can be used to provide the desired properties.
[000256] In a variety of embodiments, it is useful to use a plurality of ultracapacitors 210 together to provide a power supply. In order to provide reliable operation, individual ultracapacitors 210 can be tested in advance of use. In order to perform various types of tests, each of the 210 ultracapacitors can be tested as a single cell, in series or in parallel with multiple fixed ultracapacitors 210. The use of different metals joined by various techniques (such as welding) can reduce the ESR of the connection as well as increase the resistance of the connections. Some aspects of the connections between ultracapacitors 210 are now introduced.
[000257] In some modalities, the ultracapacitor 210 includes two contacts. The two contacts are the glass sealing pin to the metal (i.e., the passage 219) and the entire remainder of the housing 207. When connecting a plurality of ultracapacitors 210 in series, it is often desired to couple an interconnection between a bottom of the housing 207 (in the case of a cylindrical 207 housing), so that the distance to the inner threads is minimized and therefore of minimum resistance. In these embodiments, an opposite end of the interconnect is generally coupled to the pin of the glass seal to the metal.
[000258] Regarding interconnections, a common type of welding involves the use of a parallel-tip electric resistance welder. Welding can be done by aligning one end of the interconnect above the pin and by welding the interconnect directly to the pin. The use of several welds will increase the strength and connection between the interconnect and the pin. In general, when soldering to the pin, configuring a shape of the end of the interconnect to correspond well with the pin serves to ensure that there is not an excess of material superimposed on the pin which would cause a short circuit.
[000259] An opposite-ended electrical resistance welder can be used to weld the interconnect to the pin, while an ultrasonic welder can be used to weld the interconnect to the bottom of the 207 housing. Welding techniques can be used when the metals involved are compatible.
[000260] Regarding the materials used in interconnections, a common type of material used for interconnection is nickel. Nickel can be used as it welds well with stainless steel and has a strong interface. Other metals and alloys can be used in place of nickel, for example, to reduce resistance at interconnection.
[000261] In general, the material selected for the interconnection is chosen for compatibility with the materials on the pin as well as materials in the 207 housing. Exemplary materials include copper, nickel, tantalum, aluminum and nickel-copper plate. Additional metals that can be used include silver, gold, brass, platinum and tin.
[000262] In some embodiments, such as when the pin (that is, passage 219) is made of tantalum, the interconnection may use intermediate metals, such as using a short bridge connection. An exemplary bridge connection includes a tantalum strip, which has been modified using the opposite end resistance welder to weld an aluminum / copper / nickel strip to the bridge. A parallel resistance welder is then used to weld the tantalum strip to the tantalum pin.
[000263] The bridge can also be used in the contact which is the 207 housing. For example, a nickel piece can be welded by resistance to the bottom of the 207 housing. A copper strip can then be ultrasonically welded to the nickel bridge. . This technique helps to decrease the resistance of cell interconnects. The use of different metals for each connection can reduce the ESR of interconnections between cells in series.
[000264] Having then described aspects of a robust 210 ultracapacitor that is useful for high temperature environments (ie, up to about 210 degrees Celsius), some additional aspects are now provided and / or defined.
[000265] A variety of materials can be used in the construction of ultracapacitor 210. The integrity of ultracapacitor 210 is essential if oxygen and hydration are to be excluded and electrolyte 206 must be prevented from escaping. To accomplish this, seam welds and any other sealing points should meet standards for tightness over the intended temperature range for operation. In addition, the selected materials should be compatible with other materials, such as ionic liquids and solvents that can be used in the formulation of electrolyte 206.
[000266] In some embodiments, passageway 219 is formed of metal like at least one of KOVARTM (shit from Carpenter Technology Corporation of Reading, Pennsylvania, where KOVAR is a low-melt, cast-iron, nickel-cobalt expansion alloy whose chemical composition is controlled within narrow limits to ensure uniform and accurate thermal expansion properties), Alloy 252 (a nickel-iron alloy suitable for sealing glass and ceramic to metal), tantalum, molybdenum, niobium, tungsten, Stainless Steel 446 (a non-heat-treatable ferric stainless steel that offers good resistance to oxidation and corrosion by high temperature) and titanium.
[000267] The body of the glass-to-metal seals that take advantage of the previous ones can be manufactured from 300 series stainless steels, such as 304, 304L, 316 and 316L alloys. The bodies can also be made of metal like at least one of several nickel alloys, like Inconel (a family of austenitic nickel-chromium-based super alloys that are corrosion and oxidation resistant materials for service in extreme environments subjected to pressure and heat ) and Hastelloy (a highly corrosion resistant metal alloy that includes nickel and different percentages of molybdenum, chromium, cobalt, iron, copper, manganese, titanium, zirconium, aluminum, carbon and tungsten).
[000268] The insulating material between the passage 219 and the surrounding body in the glass to metal seal is typically glass, the composition of which is the property of each seal manufacturer and depends on whether the seal is under compression or is matched. Other insulating materials can be used to seal glass to metal. For example, several polymers can be used for sealing. As such, the term "glass to metal" sealing is purely descriptive of a type of seal and is not intended to imply that the seal must include glass.
[000269] Housing 207 for ultracapacitor 210 may be made, for example, of stainless steel types 304, 304L, 316 and 316L. it can also be constructed from, but not limited to, some of the aluminum alloys, such as 1100, 3003,5052, 4043 and 6061. Various multilayer materials can be used and may include, for example, stainless steel plated aluminum. Other compatible non-limiting metals that can be used include platinum, gold, rhodium, ruthenium and silver.
[000270] Specific examples of glass-to-metal seals that were used in the ultracapacitor 210 include two different types of glass-to-metal seals. The first is from SCHOTT with a US location in Elmsford, NY. This modality uses a stainless steel pin, insulating glass and a stainless steel body. A second glass to metal seal is from HERMETIC SEAL TECHNOLOGY of Cincinnatti, OH. This second modality uses a tantalum pin, glass insulator and a stainless steel body. Different sizes of the various modes can be provided.
[000271] An additional embodiment of the glass to metal seal includes a modality that uses a seal and an aluminum body. Yet another form of sealing glass to metal includes an aluminum seal using epoxy or other insulating materials (such as ceramics or silicon).
[000272] Various aspects of the glass to metal seal can be configured as desired. For example, the dimensions of the housing and pin and the material of the pin and housing can be modified as appropriate. The pin can also be a tube or solid pin, as well as having multiple pins in a cover. While the most common types of material used for the pin are stainless steel alloys, copper-core stainless steel, molybdenum, platinum-iridium, various nickel-fertile alloys, tantalum and other metals, some non-traditional materials can be used ( such as aluminum). The housing is generally formed of stainless steel, titanium and / or various other materials.
[000273] A variety of fixing techniques can be used in the assembly of the ultracapacitor 210. For example and in relation to welding, a variety of welding techniques can be used. The following is an illustrative listing of types of welding and various purposes for which each type of welding can be used.
[000274] Ultrasonic welding can be used to, among other things: weld aluminum flaps to the current collector; weld flaps to the bottom plate cover; weld a jumper flap to the plated bridge connected to the glass seal to the metal pin; and weld the jelly roll tabs together. Resistance or pulse welding can be used to, among other things: weld fillets at the bottom of the can or at the pin; weld fillets to the current collector; weld a jumper to a plated bridge; weld a plated bridge to terminal 208; weld fillets to a bottom cover. Laser welding can be used to, among other things: weld a stainless steel cover to a stainless steel can; weld a stainless steel bridge to a glass and stainless steel seal to the metal pin; and solder a plug on the fill port. TIG welding can be used for, among other things: sealing aluminum covers to an aluminum can; and weld the aluminum seal in place. Cold welding (metal compression with high strength) can be used to, among other things: seal the supply port by fitting by pressing an aluminum tack / ball on the filling port.
[000275] The physical aspects of an exemplary 210 ultracapacitor are now provided. Note that in the following tables, the terminology "tab" refers, in general, to the "fillet" as discussed above; the terms "point" and "jumper" also refer to aspects of the fillet (for example, the bridge can be attached to the passage, or "pin," while the jumper is useful for connecting the bridge to the flaps, or fillets). The use of multiple connections can facilitate the assembly process and takes advantage of certain assembly techniques. For example, the bridge can be laser-welded or pin-welded and coupled with an ultrasonic weld to the jumper.
[000276] Figures 34 to 42 are graphs that represent the performance of exemplary ultracapacitors 210 and represent the performance of ultracapacitor 210 at 1.75 volts and 125 degrees Celsius as well as the performance of ultracapacitor 210 at 1.5 volts and 150 degrees Celsius and the performance of the 210 ultracapacitor at 0.5 volts and 210 degrees Celsius. In these latter examples (210 degrees Celsius), the ultracapacitor 210 was a closed cell (that is, housing). The ultracapacitor was cycled 10 times, with a 100mA charge and discharge, charged to 0.5 Volts, resistance measurement, discharged to 10mV, 10-second rest and then cycled again.
[000277] In general, the ultracapacitor 210 can be used under a variety of environmental conditions and demands. For example, the terminal voltage can range from about 100 mV to 10 V. Ambient temperatures can range from about 40 degrees Celsius minus to 210 degrees Celsius minus. High ambient temperatures range from positive 60 degrees Celsius to positive 210 degrees Celsius.
[000278] Referring now to Figure 43, exemplary electronic components are shown in communication with at least one source 401 and at least one high temperature rechargeable energy storage 402 (HTRES, which can be, for example, the 210 ultracapacitor) . In this non-limiting example, the power supply 115 includes a charger (first subsystem) for charging the HTRES in communication with the source and the HTRES. A second subsystem in communication with the HTRES and a load can include a DC / DC power supply and / or a DC / AC power supply. Several power converters can be included in the power supply 115 and can be used between the source and the HTRES, as well as between the HTRES and a load.
[000279] The power source 401 which is included in the power supply 115 can include a variety of power inputs. Power inputs can generally be divided into three categories. The categories include primary batteries, remote systems and generators.
[000280] In some embodiments, the power supply includes a primary battery as part of the 401 power source. Exemplary batteries include those that are adapted to operate in a harsh environment. Specific examples include several chemical batteries, which include those with lithium. More specific examples include lithium-thionyl-chloride (Li-SOCl2) and batteries based on similar and / or chemical technologies. However, it is recognized that some of these technologies may not be able to achieve the desired temperature ratings and that some of these technologies can only support energy storage in the short term (ie energy storage may include, for example, elements that are not rechargeable, or that have a shortened life compared to other elements). Other exemplary batteries that can be included in power supply 115 include lithium-bromine-chloride, as well as lithium-sulfuryl-chloride and molten salt.
[000281] The 401 source can include at least one connection to a remote power supply. That is, the energy can be supplied through an external source, such as through a steel cable. Since external energy sources are not restricted by the downhole environment, the primary concern for receiving energy includes methods and apparatus for communicating energy to the downhole. Exemplary techniques for communicating power to the logging instrument 100 and the power supply 115 include a wired compartment, wired tube, coiled tubing and other sets of technical procedures that may be known in the art.
[000282] Refer to Figures 44 to 50, in which aspects of power conversion circuits are shown. As shown in Figure 44, an exemplary embodiment of the first subsystem 152 includes a first switching device 161 and a second switching device 162 as well as a filter inductor 163. External power supply 151 can couple with the first subsystem 152 and the HTRES 402 (for example, a high temperature ultracapacitor). The action of the first switching device 161 and the second switching device 162 can be controlled to achieve the battery conditioning and current limiting features described above. Specifically, the relative activated time of the first switching device 161 and the second switching device 162 which operates in a complementary manner (working rate) can be used to justify the conversion rate and the current flow. The first example subsystem 152 shown in Figure 44 can be useful when the voltage of the external power supply 151 is higher in value compared to the voltage of HTRES 402. Current regulation or limitation can be achieved by means of a control system feedback (not shown).
[000283] An exemplary modality of the second subsystem 153 includes DC-DC or DC-AC power converters depending on the tool requirements. A function of a second subsystem 153 may be to regulate the voltage or current delivered to the load (for example, the logging instrument 100 and / or the downhole electronics 113). Due to the capacitive nature of the HTRES 402, when deployed with an ultracapacitor, the voltage of the HTRES 402 can decrease in an approximately linear fashion as the load is removed from the HTRES 402. A function of the second subsystem 153 can then be to regulate the voltage or current delivered to the logging instrument 100, despite the variation voltage presented by HTRES 402. Voltage regulation or limitation can be achieved through a feedback control system (not shown).
[000284] As shown in Figure 45, an exemplary embodiment of the second subsystem 153 can include respective modalities of the first switching device 161, the second switching device 162 as well as the filter inductor 163. The load can couple to the second subsystem 153 and to HTRES 402. The action of the respective modalities of the first switching device 161 and the second switching device 162 can be controlled to achieve the voltage or current regulation features described above. Specifically, the working ratio of the relative active time of the respective modalities of the first switching device 161 and the second switching device 162 can be used to adjust the conversion ratio and the current flow or voltage displayed. The second exemplary subsystem 153 shown in Figure 45 can be useful when the required voltage is higher in value compared to the voltage of the HTRES 402. Voltage regulation or limitation can be achieved through a feedback control system (not shown) .
[000285] As shown in Figure 46, the first subsystem 152 and the second subsystem 153 can be coupled together and also to HTRES 402 to provide a power supply modality 115. In this modality, the exemplary power supply 115 can be particularly advantageous when the terminal voltage of the external power supply 151 is higher in value or lower in value compared to the terminal voltage of the load since the terminal voltage of the HTRES 402 is lower in value than both.
[000286] Power converters can, in general, be of any topology. Non-limiting examples include converters commonly called "buck," "boost," "buck-boost," "Cúk," "switching capacitor," and isolated versions of non-isolated converters (for example, "return," "forward , "), as well as cascades from any of these converters (e.g., buck + boost).
[000287] An example converter 181 is shown in Figure 47. In this example, converter 181 is a bidirectional buck converter. This mode is suitable for, among other things, use as a power converter when the output voltage is required to be less than the input voltage.
[000288] Another example converter 181 is shown in Figure 48. In this example, converter 181 is a bidirectional boost converter. An additional exemplary converter 181 is shown in Figure 49. In this example, converter 181 is a mixed bidirectional buck-boost converter.
[000289] An exemplary modality of the feedback controller 182 is provided in Figure 50. The components shown in it can be deployed in digital or analog domains, or in a combination, as determined appropriate by a designer, manufacturer or user. The feedback controller 182 may include elements for monitoring and controlling various properties. For example, feedback controller 182 may include components for frequency compensation, pulse width modulation, dead time protection, working time limitation, providing a smooth start (i.e., rising voltage) and the like.
[000290] High temperature electronic components are used to provide signal conditioning, telemetry and electronic power components and are, in general, adapted for operation at temperatures as high as about 200 degrees Celsius and in some modalities, up to about 300 degrees Celsius. The non-limiting modalities of high temperature electronic components include integrated and separate ready-to-use silicon-on-insulator and separate unshielded silicon devices as well as active silicon carbide power devices. Some commercially available low temperature and high nominal temperature passive ceramic components (COG or NPO dielectrics) and high temperature passive magnetic components can be used. In exemplary embodiments, substrate material for the circuit will be polyimide, high temperature epoxy, or AlN (aluminum nitrite) ceramics, which are chosen for their excellent thermal conductivity and thermal stability. In some of these modalities, the circuit interconnections will be oxidation resistant Au tracks. The bonding strategies will employ Au wire or flip chip bonding to active components without a shell using AuGe high temperature solder, and / or similar types of bonding. However, for some deployments Au wire bonding is expected to be advantageous over flip chip bonding due to additional mechanical submission in the presence of thermal expansion and shock and vibration. A non-exhaustive list of suppliers for all of the above components is included in the table below: Table 5 High Temperature Circuit Component Suppliers

[000291] In the form of a charger for at least one ultracapacitor 10, the electronic components include a dual function regulated buck converter, which limits its own current in the event of a low voltage in at least one ultracapacitor 10 and regulates your tension in another way. In some embodiments, the regulated DC / DC converter includes a suitable topology to deploy a regulated boost converter for wide input voltage feedback to provide a stable voltage bus.
[000292] A person skilled in the art will recognize that the 115 power supply can be used in conjunction with technologies and instrumentation in support of resistivity, capacitance, nuclear including pulsed neutron and range measurement, passive range measurement, as well as others , magnetic resonance imaging, acoustic and / or seismic measurements, flow measurements, various sampling protocols, communications, data storage and processing, geological targeting and a myriad of other requirements for downhole power use. A large complement of components can also be powered by the 115 power supply. Non-limiting examples include accelerometers, magnetometers, sensors, transducers, digital and / or analog devices (which include those listed below) and the like.
[000293] Among other things, the production logging instrument 100 makes it possible to use higher, thinner, stronger and cheaper lines and cables of higher bandwidth. Due, at least in part, to the properties of energy storage 42, the use of conventional copper cable 8 can be replaced with steel cable, fiber optic line and other types of cable and line. In some embodiments, the production logging instrument 100 operates independently, such as when equipped with an onboard generator 41. Exemplary steels include types 304, 304L, 316 and 316L as well as carbon steel. In general, a type of steel will be chosen for its corrosion resistance, mechanical strength and electrical conductivity. 316 stainless steel is a common choice for some long-life downhole components that include cable protection.
[000294] Including HTRES in the logging instrument, new types of cables and means of transmission become practical. For example, HTRES can be loaded slowly by "slow loading" over a relatively short period of time, for example several hours and then supply power to the rest of the logging instrument for normal operation in relatively short bursts, for example several minutes. In this mode of operation, the cable resistance for power transmission can be substantially greater than in the prior art. For example, a cable can be used with an inner steel conductor in place of the inner copper conductor of prior art cables. Keeping the diameter fixed and choosing a carbon steel inner conductor, the cost of the inner conductor material will be approximately 13% of that for a copper inner conductor. The tensile strength of the carbon steel inner conductor will be approximately 7,000% of that of the copper inner conductor. However, the resistance of the carbon steel inner conductor will be approximately 8,500% of that of the copper inner conductor.
[000295] For a 22 AWG inner conductor, a copper conductor would display approximately 16.14 Ohms by 304.8 meters (1,000 feet), while a carbon steel inner conductor would display approximately 137 Ohms per 1,000 ft. A typical well may require a cable of approximately 3,048 meters (10,000 feet) that yields corresponding cable resistances of 161 Ohms and 1,370 Ohms respectively. For a 48 V power supply on a surface, the maximum powers available at the cable ends are 3.57 W and 420 mW respectively. Although 3.57 W may be sufficient to perform typical logging instruments, 420 mW would be prohibitively limiting. On the other hand, having the HTRES attached to the logging instrument, the system can slow load the HTRES with the available 420 mW until enough energy has been accumulated and then feed the loads into a typical logging instrument. This analysis assumes that the cable comprises an outer conduction protection that serves as a second conductor and that the protection has negligible resistance compared to that for the inner conductor.
[000296] The project example above can be exchanged in a number of ways. For example, the cable can be designed to exhibit a smaller outside diameter than prior art cables, again due to the fact that the slow charge method accommodates superior resistance in the cable. For example, a cable can be designed with a 22 AWG inner lead gauge where a 10 AWG inner lead gauge was required for a prior art project. The resulting cable diameter is approximately 25% of the prior art cable in this example. A benefit of the smaller cable diameter is the resulting decrease in fluid flow obstruction.
[000297] The cable can also employ smaller internal copper conductors. It may employ fewer conductors, for example, where a conductor transmits all the required power to the loads instead of transmitting the power through multiple conductors.
[000298] In one embodiment, the benefit of a smaller simplified cable can be amplified for multiple purposes by one or less conductors (compared to prior art designs). For example, while in prior art designs, multiple conductors have been used to provide power for multiple aspects of a logging tool, a single conductor can be used to provide all the required power. In another example, a single conductor can be used to provide all the power required for a plurality of logging tools, such as those arranged at different locations within the well. In this project, each of the logging tools can include control of their respective electronic components to provide subjection to the slow load of a respective HTRES, while accommodating power delivery to other tools. For example, a control algorithm can limit current draw from a cable so that the resulting voltage in other tools also accommodates useful current draw. This control algorithm can use a priori known resistance values of the cable used in the application, length of said cable, respective inter-tool lengths of said cable and a physical order of the respective tools along the borehole. In another example, a single conductor can have multiple purposes for both the transmission of power and information. The transmission of information can be bidirectional, that is, from the surface to the tool and from the tool to the surface, or it can be unidirectional. For example, an electrical signal, for example, a sinusoid, can be superimposed on a nominal DC voltage. The superimposed sinusoid can be modulated by frequency or amplitude to carry information to a tool. Another method includes time multiplexing of power and information transmission. For example, power can be transferred over a period of time after which information is transferred over a separate period of time. Numerous other methods can be used to combine information and power transmission into an aggregate electrical signal or to use one or a few cables to transmit information and power in multiple ways.
[000299] Because steel is generally more resistant to corrosion and mechanical stress compared to copper, different cable configurations also become practical. For example, the cable can be a pair of steel conductors and insulated with or without encapsulation, but without protection when H2S is not present in substantial concentrations.
[000300] Other methods of transmitting power and information may become practical. For example, the fiber optic cable can provide a minimum amount of power and a high rate of information transfer through the laser light. The relatively minimal amount of transmitted power can be used as a power source to slow the HTRES load. For example, electrical power light transducers include photodiodes and phototransistors. Including this transducer in a logging tool and attaching said tool to a fiber optic line and attaching said fiber optic line to a light source on the surface creates a means for transmitting both power and information between the surface and the tool. Advantageously, the materials typically used in the manufacture of a fiber optic line are, in general, less susceptible to corrosion compared to electrical (metallic) conductors and therefore require less protection from the drilled hole environment.
[000301] The use of stronger cable materials despite high electrical resistivity may also allow double use of the cable for electrical transmission and for mechanical purposes. For example, a shield or encapsulation or mechanical support otherwise added from a cable for added protection or tensile strength in various transportation methods may not be required when a steel inner conductor is used in place of a copper inner conductor. In a pipeline-carried permanent downhole logging tool, a PDC in prior art designs can be protected to prevent mechanical stress on an internal copper conductor during insertion into the well, although the PDC may not provide substantial traction support. In the current design, an internal steel conductor provides up to 150% more break resistance compared to prior art copper designs, eliminating or reducing the need for additional protection. In another example, a cable made with steel inner conductor material can be used in production logging activities where the tool is moved vertically in the well. In this example, the cable provides substantial traction support. This system can be used for both permanent logging and vertical logging activities, for example, it can be moved vertically by winding the cable on the surface and then can be left in the well at a fixed location for a period of long time, for example, several weeks or months. In some embodiments, a cable may use internal steel conductors or steel conductors in parallel, twisted, or otherwise paired configurations. Other materials for said conductor can also be used as deemed appropriate by the designer to achieve concessions in mechanical strength, corrosion resistance, temperature stability, electrical resistance, mechanical density or otherwise. Examples of other potentially useful materials include titanium, aluminum, nickel, silver, gold and alloys.
[000302] Other types of ultracapacitors can be used for storing energy 42. Additionally, battery modalities can be used with or in place of an ultracapacitor.
[000303] Having described the aspects of the production logging instrument 100 and some of its capabilities, it should now be apparent that producers can use the data collected from the production logging in a variety of ways. For example, dynamic mapping of production areas can be achieved, where production between several wells is related. The various parameters tracked and evaluated can be used to predict meaningful information, such as future well locations, well depletion, current situation assessment and the like. These activities can be greatly enhanced through the use of software running on a computer (that is, machine-executable instructions stored in machine-readable media).
[000304] Having then described certain aspects of the invention, the additional benefits and features are now discussed. Through the use of the production logging instrument provided in this document, users are equipped with the capabilities to characterize and monitor downhole conditions on an ongoing basis. Measurements can be performed on a real-time basis, an almost real-time basis, or periodically as appropriate and as otherwise described in this document.
[000305] In support of the teachings in this document, several components of analysis can be used, including a digital system and / or an analog system. The system (s) may have components such as a processor, storage media, memory, input, output, various communications links (wired, wireless, pulsed fluid, optical or other), user interfaces , software and firmware programs, signal processors (digital or analog) and other similar components (such as resistors, capacitors, inductors, pumps, sensors, fluid storage, sampling apparatus and other similar components) to provide the operation and analysis of the apparatus and methods disclosed in this document in any of the various forms well appreciated in the art. It is considered that these teachings may or may not be implemented in conjunction with a set of computer-executable instructions stored in a computer-readable medium, which includes memory (ROMs, RAMs), optical (CD-ROMs), or magnetic (disks, hard drives), or any other type that when executed causes a computer to implant the method of the present invention. These instructions can provide equipment operation, control, data collection and analysis and other functions deemed relevant by a system designer, owner, user or other similar person, in addition to the functions described in this disclosure.
[000306] A person skilled in the art will recognize that the various components or technologies may provide certain beneficial or necessary features or functionality. Consequently, these functions and features, as may be necessary in supporting the appended claims and variations thereof, are recognized as being inherently included as a part of the teachings in this document and a part of the disclosed invention.
[000307] Although the invention has been described with reference to the exemplary modalities, those skilled in the art will understand that various changes can be made and equivalents can be replaced by elements thereof without departing from the scope of the invention. In addition, many modifications will be appreciated by those skilled in the art to adapt a particular instrument, situation or material to the teachings of the invention without departing from its essential scope. Therefore, it is intended that the invention is not limited to the particular modality disclosed as the best way contemplated for carrying out that invention, but that the invention will include all modalities covered by the scope of the appended claims.

权利要求:
Claims (14)
[0001]
1. Logging system characterized by the fact that it comprises: a logging instrument (10) including a rechargeable energy storage (402) and electronics (13); and a cable (8) configured to charge the rechargeable energy storage (402) from a remote power supply (45); wherein the rechargeable energy storage (402) is a high temperature rechargeable energy storage (402) comprising a rechargeable ultracapacitor (210) with an operating temperature range of 80 ° C to 210 ° C with a volumetric leakage current (I / L) of less than 1,000 mA (Ma) per liter within this temperature range and voltage range; wherein the rechargeable ultracapacitor (210) is coupled to a power supply (151) permanently installed in a rock bottom location (1); wherein the rechargeable ultracapacitor (210) comprises: a plurality of electrodes (203) immersed in an electrolytic, where each electrode (203) comprises a current collector (202) through which carbon nanotubes are arranged; the rechargeable energy storage (402) is configured to be charged repeatedly using energy from the power supply (151) for periods of a first duration at a first energy level and to repeatedly supply power to electronics (13) for periods of a second duration on a second energy level, where the first duration is greater than the second duration and the first power level is less than the second power level; and the rechargeable ultracapacitor (210) is configured to have a leakage current of less than 1 amp per liter and a maximum rated operating voltage of at least 0.5 volts.
[0002]
2. System according to claim 1, characterized by the fact that the rechargeable ultracapacitor (210) has an operating temperature range of -40 ° C to 210 ° C with a volumetric leakage current of less than 1 amp per liter within the entire operating temperature range.
[0003]
3. System according to claim 1 or 2, characterized by the fact that the rechargeable ultracapacitor (210) has a maximum voltage of 4V, at room temperature.
[0004]
4. System according to claim 1 or 2, characterized by the fact that the rechargeable ultracapacitor (210) is configured to operate with a reduced maximum voltage of 0.5 V at temperatures above 210 ° C.
[0005]
5. System according to any one of claims 1 to 4, characterized by the fact that the electronics (13) are configured to operate at temperatures as high as 200 ° C.
[0006]
6. System according to any one of claims 1 to 5, characterized by the fact that the electronics (13) are configured to operate at temperatures as high as 300 ° C.
[0007]
7. System, according to claim 1, characterized by the fact that the logging instrument (10) is configured for operation in a well hole (1), and in which the cable (8) is configured to load slowly rechargeable energy storage (402) from the remote power source located outside the well bore (1).
[0008]
8. System, according to claim 7, characterized by the fact that: the energy provided by the slow charge for the rechargeable energy source is less than the power required to operate the logging system; and the rechargeable power source is configured to be charged by the slow charge for several hours and then supply power to the logging system for several minutes.
[0009]
9. System according to claim 8, characterized by the fact that the cable (8) comprises an internal steel conductor.
[0010]
System according to any one of claims 7 to 9, characterized in that the cable (8) comprises a single conductor to supply all the required power.
[0011]
11. System according to claim 10, characterized by the fact that the logging instrument (10) comprises a plurality of downhole tools (1), each having a respective rechargeable energy storage (402) , wherein each tool of the plurality of tools is configured to control its respective electronics (13) to supply for slow load the respective rechargeable energy source while accommodating the power supply for other tools.
[0012]
12. System according to any of claims 7 to 11, characterized by the fact that the cable (8) is multi-purpose, both for energy transmission and for information transmission.
[0013]
13. System according to claim 12, characterized by the fact that the system is configured to superimpose an electrical signal on a DC voltage in the cable (8) to transmit the information.
[0014]
14. The system according to claim 7, characterized by the fact that: the cable (8) comprises a fiber optic cable configured to provide a minimum amount of energy and a high rate of information transfer by means of laser light; the minimum amount of transmitted power is used as an energy source to slowly charge the rechargeable energy storage (402); and the rechargeable power source is configured to be charged by the slow charge for several hours and then supply power to the logging system for several minutes.

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法律状态:
2018-12-04| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2019-11-19| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-06-23| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|

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2020-10-13| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-12-29| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 05/11/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US201161555100P| true| 2011-11-03|2011-11-03|

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US61/555,100|2011-11-03|

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US201261624080P| true| 2012-04-13|2012-04-13|

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US61/624,080|2012-04-13|

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PCT/US2012/063621|WO2013067540A1|2011-11-03|2012-11-05|Production logging instrument|

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