Ultracapacitor energy storage cell pack and methods of assembling and cooling the same

An ultracapacitor energy storage cell pack, comprising:

• an ultracapacitor mounting assembly including a circuit board;
• a plurality of capacitors including a pair of terminals, the plurality of capacitors mounted to at least the circuit board of the ultracapacitor mounting assembly with the pair of terminals;
• and
• a sealing material to seal the pair of terminals of the capacitors against collection of water, dust, and debris that may tend to contaminate and corrode the terminals and otherwise degrade the performance of the capacitors.

An ultracapacitor energy storage cell pack, comprising:

• a plurality of capacitors including a pair of terminals;
• a plurality of electrically conductive interconnects to connect the capacitors via the terminals;
• and
• an ultracapacitor mounting assembly to which the plurality of capacitors are mounted, the ultracapacitor mounting assembly including means for mounting, carrying and sealing the electrically conductive interconnects, means for maintaining the position and spacing of the capacitors in an X and Y direction, means for holding down the capacitors in a Z direction, means for preventing the capacitors from rotating, and means for mounting the capacitors to the ultracapacitor mounting assembly via the pair of terminals.

An ultracapacitor energy storage cell pack, comprising:

• a plurality of capacitors including a pair of terminals and a cover;
• a plurality of electrically conductive interconnects including holes through which the terminals may pass, the electrically conductive interconnects connecting the capacitors via the terminals;
• and
• an ultracapacitor mounting assembly to which the plurality of capacitors are mounted, the ultracapacitor mounting assembly including a bottom base plate on which the capacitors are located and a crate plate with a plurality of holes through which the capacitors are received, a box frame including large lower and upper openings through which the capacitors extend, a first insulating and sealing sheet located on the cover of the capacitors and including a plurality of holes through which the terminals protrude, a second insulating and sealing sheet located on top of the first sheet and including a plurality of holes that receive the plurality of electrically conductive interconnections, the holes of the electrically conductive interconnections receiving the terminals of the capacitors, one or more circuit boards located on top of the second insulating and sealing sheet and including holes through which the terminals protrude, and fasteners to attach the terminals to the one or more circuit boards to compress the first and second insulating and sealing sheets in between the cover of the capacitors and the one or more circuit boards, and secure the capacitors and electrically conductive interconnections in position.

A method of assembling an ultracapacitor energy storage cell pack having a plurality of capacitors with a cover, a pair of terminals protruding from the cover, an exterior casing, comprising:

• inserting a plurality of capacitors through holes in a crate plate, on top of a bottom base plate;
• disposing a box frame over the capacitors so that the capacitors extend through large lower and upper openings of the box frame;
• placing a first insulating and sealing sheet on top of the capacitors so that the terminals protrude through holes in the sheet;
• placing a second insulating and sealing sheet on top of the first sheet, the second insulating and sealing sheet including a plurality of holes to receive a plurality of electrically conductive interconnections;
• locating a plurality of electrically conductive interconnections in the plurality of holes of the second insulating and sealing sheet so that the terminals of the capacitors extend through holes in the electrically conductive interconnections;
• placing one or more circuit boards on top of the second insulating and sealing sheet so that the terminals protrude through the one or more circuit boards;
• attaching the terminals to the one or more circuit boards using fasteners, compressing the first and second insulating and sealing sheets in between the cover of the capacitors and the one or more circuit boards, and securing the capacitors and electrically conductive interconnections in position.