Power system for high temperature applications with rechargeable energy storage

• US 9,013,144 B2
• Filed: 05/24/2012
• Issued: 04/21/2015
• Est. Priority Date: 12/21/2010
• Status: Active Grant

• Current Assignee: FastCAP Systems Corporation
• Original Assignee: FastCAP Systems Corporation
• Inventors: Cooley, John, Signorelli, Riccardo, Green, Morris, Kuttipillai, Padmanaban Sasthan, Deane, Christopher, Wilhelmus, Lindsay A.
• Primary Examiner(s): Dinh, Paul
• Assistant Examiner(s): AISAKA, BRYCE M
• Application Number:
  US13/480,085
• Publication Number:
  US 20120268074A1
• Time in Patent Office: 1,062 Days
• Field of Search: 320/112
• US Class Current: 320/112
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: E21B 41/0085 Adaptations of electric power generating means for use in boreholes
• CPC Class Codes: H01G 11/08 Structural combinations, e.g. assembly or connection, of hybrid or EDL capacitors with other electric components, at least one hybrid or EDL capacitor being the main component
• CPC Class Codes: H01G 11/10 Multiple hybrid or EDL capacitors, e.g. arrays or modules housings, cases, encapsulations or mountings thereof H01G11/78
• CPC Class Codes: H01G 11/14 Arrangements or processes for adjusting or protecting hybrid or EDL capacitors emergency protective circuit arrangements specially adapted for capacitors, and effecting automatic switching in the event of an undesired change from normal working conditions H02H7/16; emergency protective circuit arrangements for limiting excess current or voltages without disconnection H02H9/00
• CPC Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01G 11/36 Nanostructures, e.g. nanofibres, nanotubes or fullerenes
• CPC Class Codes: H01G 11/58 Liquid electrolytes
• CPC Class Codes: H01G 11/60 characterised by the solvent
• CPC Class Codes: H01G 11/62 characterised by the solute, e.g. salts, anions or cations therein
• CPC Class Codes: H01G 11/78 Cases; Housings; Encapsulations; Mountings
• CPC Class Codes: H01G 2/065 for surface mounting, e.g. chip capacitors
• CPC Class Codes: H01M 10/39 working at high temperature
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/4257 Smart batteries, e.g. electronic circuits inside the housing of the cells or batteries
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/46 Accumulators structurally combined with charging apparatus circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 16/00 Structural combinations of different types of electrochemical generators
• CPC Class Codes: H01M 2010/4271 Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
• CPC Class Codes: H01M 2010/4278 : Systems for data transfer from batteries, e.g. transfer of battery parameters to a controller, data transferred between battery controller and main controller
• CPC Class Codes: H01M 2220/10 : Batteries in stationary systems, e.g. emergency power source in plant
• CPC Class Codes: H01M 50/107 : having curved cross-section, e.g. round or elliptic H01M50/103, H01M50/109, H01M50/11 take precedence
• CPC Class Codes: H02J 7/0042 : characterised by the mechanical construction
• CPC Class Codes: H02J 7/0068 : Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/0071 : with a programmable schedule
• CPC Class Codes: H02J 7/345 : using capacitors as storage or buffering devices
• CPC Class Codes: Y02E 60/13 : Energy storage using capacitors
• CPC Class Codes: Y10T 29/49108 : Electric battery cell making
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing

Abstract

A power system adapted for supplying power in a high temperature environment is disclosed. The power system includes a rechargeable energy storage that is operable in a temperature range of between about seventy degrees Celsius and about two hundred and fifty degrees Celsius coupled to a circuit for at least one of supplying power from the energy storage and charging the energy storage; wherein the energy storage is configured to store between about one one hundredth (0.01) of a joule and about one hundred megajoules of energy, and to provide peak power of between about one one hundredth (0.01) of a watt and about one hundred megawatts, for at least two charge-discharge cycles. Methods of use and fabrication are provided. Embodiments of additional features of the power supply are included.

Claims

1. A power system adapted for supplying power in a high temperature environment, the power system comprising:

a rechargeable energy storage that is operable in a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius coupled to a circuit for at least one of supplying power from the energy storage and charging the energy storage;

wherein the energy storage is configured to store between about one one hundredth (0.01) of a joule and about one hundred megajoules of energy, and to provide peak power of between about one tenth (0.10) of a watt and about one hundred megawatts, for at least two charge-discharge cycles; and

wherein the rechargeable energy storage comprises an ultracapacitor comprising electrochemical double-layer capacitor comprising;

two electrodes wetted with an electrolyte, each electrode being attached to or in contact with or coated onto a current collector and separated from each other by a separator porous to the electrolyte,

wherein the electrodes, electrolyte and current collector contain less than 1,000 parts per million (ppm) of impurities, and

wherein the ultracapacitor exhibits a leakage current less than 1 amp per liter of volume over a range of operating temperatures and at a voltage up to a rated voltage.

2. The power system of claim 1, wherein the operating range of temperatures comprises between about seventy degrees Celsius and about two hundred degrees Celsius.

3. The power system of claim 1, wherein the operating range of temperatures comprises between about seventy degrees Celsius and about one hundred seventy five degrees Celsius.

4. The power system of claim 1, wherein the operating range of temperatures comprises between about seventy degrees Celsius and about one hundred and fifty degrees Celsius.

5. The power system of claim 1, wherein the operating range of temperatures comprises between about seventy degrees Celsius and about one hundred and twenty five degrees Celsius.

6. The power system of claim 1, wherein the operating range of temperatures comprises between about eighty degrees Celsius and about two hundred and ten degrees Celsius.

7. The power system of claim 1, wherein the operating range of temperatures comprises between about ninety degrees Celsius and about two hundred and ten degrees Celsius.

8. The power system of claim 1, wherein the operating range of temperatures comprises between about one hundred degrees Celsius and about two hundred and ten degrees Celsius.

9. The power system of claim 1, wherein the operating range of temperatures comprises between about one hundred twenty five degrees Celsius and about two hundred and ten degrees Celsius.

10. The power system of claim 1, wherein operating range of temperatures comprises between about one hundred twenty six degrees Celsius and about two hundred and ten degrees Celsius.

11. The power system of claim 1, wherein the operating range of temperatures comprises between about one hundred fifty degrees Celsius and about two hundred and ten degrees Celsius.

12. The power system of claim 1, wherein the energy storage is configured to store between about one tenth (0.1) of a joule and about one hundred megajoules of energy.

13. The power system of claim 1, wherein the energy storage is configured to store between about one joule and about one hundred megajoules of energy.

14. The power system of claim 1, wherein the energy storage is configured to store between about ten joules and about one hundred megajoules of energy.

15. The power system of claim 1, wherein the energy storage is configured to store between about one hundred joules and about one hundred megajoules of energy.

16. The power system of claim 1, wherein the energy storage is configured to store between about one thousand joules and about one hundred megajoules of energy.

17. The power system of claim 1, wherein the energy storage is configured to store between about one one hundredth (0.01) of a joule and about ten megajoules of energy.

18. The power system of claim 1, wherein the energy storage is configured to store between about one one hundredth (0.01) of a joule and about one megajoule of energy.

19. The power system of claim 1, wherein the energy storage is configured to store between about one one hundredth (0.01) of a joule and about one hundred thousand joules of energy.

20. The power system of claim 1, wherein the energy storage is configured to store between about one one hundredth (0.01) of a joule and about ten thousand joules of energy.

21. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about one tenth (0.10) of a watt and about one hundred megawatts.

22. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about one watt and about one hundred megawatts.

23. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about ten watts and about one hundred megawatts.

24. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about one hundred watts and about one hundred megawatts.

25. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about one one hundredth (0.01) of a watt and about ten megawatts.

26. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about one tenth (0.10) of a watt and about one megawatt.

27. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about one tenth (0.10) of a watt and about five hundred thousand watts.

28. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about one tenth (0.10) of a watt and about one hundred thousand watts.

29. The power system of claim 1, wherein the energy storage is configured to provide peak power of between about one tenth (0.10) of a watt and about ten thousand watts.

30. The power system of claim 1, wherein the energy storage is configured to charge and discharge for at least 10 cycles.

31. The power system of claim 1, wherein the energy storage is configured to charge and discharge for at least 100 cycles.

32. The power system of claim 1, wherein the energy storage is configured to charge and discharge for at least 1,000 cycles.

33. The power system of claim 1, wherein the energy storage is configured to charge and discharge for at least 10,000 cycles.

34. The power system of claim 1, wherein the energy storage comprises at a battery and the ultracapacitor.

35. The power system of claim 1, wherein the energy storage comprises an appearance that is one of cylindrical, annular, ring-shaped, flat, prismatic, stacked, box-like, and flat prismatic.

36. The power system of claim 1, wherein the power system is configured to supply power to a logging instrument.

37. The power supply of claim 36, wherein the logging instrument comprises at least one of a coring tool, a shut-in tool, a nuclear magnetic resonance imaging (NMR) tool, an electromagnetic (EM) telemetry tool, a mud-pulser telemetry tool, a resistivity measuring tool, a gamma sensing tool, a pressure sensor tool, an acoustic sensor tool, a seismic tool, a nuclear tool, a pulsed neutron tool, a formation sampling tool and an induction tool.

38. The power system of claim 1, wherein a load comprises at least one of electronic circuitry, a transformer, an amplifier, a servo, a processor, data storage, a pump, a motor, a sensor, a thermally tunable sensor, an optical sensor, a transducer, a light source, a scintillator, a pulser, a hydraulic actuator, an antenna, a single channel analyzer, a multi-channel analyzer, a radiation detector, an accelerometer and a magnetometer.

39. The power system of claim 1, wherein the circuit comprises at least one of:

a processor, a power converter, a transistor, an inductor, a capacitor, a switch, a data storage and a bus.

40. The power system of claim 1, further comprising machine executable instructions stored in a data storage for execution by a processor.

41. The power system of claim 1, further comprising an interface for coupling to an external energy supply.

42. The power system of claim 41, wherein the external energy supply comprises at least one of a connection provided via wireline, a generator, and a battery.

43. The power system of claim 1, wherein the circuit is further configured to draw power from a plurality of types of energy storage devices.

44. The power system of claim 1, wherein the circuit comprises a circuit for at least one of:

simulating an electrical signal;

monitoring a state of charge of the energy storage;

governing change-over from a first type of energy storage to a second type of energy storage;

changing modes of operation;

monitoring system health;

storing and retrieving data;

automatically adjusting an output voltage;

entering a sleep mode;

entering a state of low-power operation; and

bypassing at least one component of the power system.

45. The power system of claim 1, wherein the circuit is further configured for monitoring at least one of temperature, vibration, shock, voltage and current.

46. The power system of claim 1, wherein the circuit comprises at least one redundant component.

47. A method using a power system, the method comprising:

selecting the power system of claim 1; and

operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius while maintaining a voltage of between about 0.1 Volts to about 4 Volts on the ultracapacitor for at least one hour;

wherein, at the end of the hour, the ultracapacitor exhibits a leakage current less than 1,000 mAmp per liter of volume over the range of operating temperature.

48. A method of using the power system of claim 1, the method comprising:

selecting the power system of claim 1,

coupling the rechargeable energy storage configured for high temperature operation with electronics configured for high temperature operation; and

operating the power system by withdrawing pulses of power from an output of the power system, wherein each pulses comprises a peak value of at least 100 W and a total power-time product (energy) of at least 100 J;

wherein, during operation, the ultracapacitor exhibits a leakage current less than 1,000 mAmp per liter of volume.

49. The power system of claim 1, wherein the two electrodes, the separator, and the electrolyte each have a low respective moisture concentration and a low respective impurity content.

50. The power system of claim 49, wherein the respective moisture concentration of the electrolyte is less than 500 parts per million (ppm) over the weight or volume of the electrolyte and the respective impurity content of the electrolyte is less than 1,000 ppm over the weight or volume of the electrolyte.

51. The power system of claim 50, wherein the respective moisture concentration adsorbed on the electrode is less than 1,000 ppm over the weight of the electrode and the respective impurity content of the electrode is less than 1,000 ppm over the weight of the electrode.

52. The power system of claim 51 wherein the respective moisture concentration adsorbed on the separator is less than 1,000 ppm over the weight of the separator and the respective impurity content of the separator is less than 1,000 ppm over the weight of the separator.

53. The power system of claim 52, wherein the electrolyte comprises less than 500 ppm of moisture, less than 1,000 ppm total concentration of halides, and less than 2,000 ppm total concentration of metallic species comprising at least one of Br, Cd, Co, Cr, Cu, Fe, K, Li, Mo, Na, Ni, Pb, Zn, at least one alloy of the foregoing metallic species, and at least one oxide of the foregoing metallic species.

54. The power system of claim 53, wherein each electrode comprises carbon nanotubes.

55. The power system of claim 53, wherein each electrode comprises carbon fibers, activated carbon, rayon, aerogel, graphene, carbon cloth, carbon nanotubes, or any combination thereof.

56. The power system of claim 53, wherein each electrode comprises carbon nanotubes and another form of nano-form carbon.

57. The power system of claim 1, wherein the rechargeable energy storage is configured to:

receive relatively constant and relatively low power electrical input from an energy supply;

output a relatively less constant and relatively high power pulsed electrical output to a downhole instrument,

wherein the downhole instrument is characterized by an operation power requirement greater than that which can be supplied by the energy supply.

58. The power system of claim 57, wherein the rechargeable energy storage is configured to provide the high power pulsed electrical output at temperatures greater than 175 degrees Celsius.

59. The power system of claim 58, wherein the rechargeable energy storage is configured to provide the high power pulsed electrical output at temperatures greater than 200 degrees Celsius.

60. The power system of claim 59, wherein the rechargeable energy storage is configured to provide the high power pulsed electrical output at temperatures greater than 210 degrees Celsius.

61. The power system of claim 58, wherein the high power pulsed electrical output is characterized by a peak power of greater than about 100 W.

62. The power system of claim 58, wherein the high power pulsed electrical output is characterized by a peak power of greater than about 1 kW.

63. The power system of claim 60, wherein the high power pulsed electrical output is characterized by a peak power of greater than about 100 W.

64. The power system of claim 60, wherein the high power pulsed electrical output is characterized by a peak power of greater than about 1 kW.

65. The power system of claim 61, wherein the instrument comprises an EM telemetry device.

66. The power system of claim 62, wherein the instrument comprises an EM telemetry device.

67. The power system of claim 63, wherein the instrument comprises an EM telemetry device.

68. The power system of claim 64, wherein the instrument comprises an EM telemetry device.

69. The power system of claim 67, wherein the high power pulsed electrical output is has a peak voltage of at least about 0.5 V.

70. The power system of claim 61, wherein the instrument comprises a mud pulse telemetry device.

71. The power system of claim 62, wherein the instrument comprises a mud pulse telemetry device.

72. The power system of claim 63, wherein the instrument comprises a mud pulse telemetry device.

73. The power system of claim 64, wherein the instrument comprises a mud pulse telemetry device.

74. The power system of claim 63, wherein high power pulsed electrical output has a peak voltage of at least 0.5 V.

75. The power system of claim 1, wherein the power system is configured to withstand shocks of up to at least about 35 times the gravitational acceleration of the Earth.

76. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures greater than 150 degrees Celsius.

77. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures greater than 175 degrees Celsius.

78. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures greater than 210 degrees Celsius.

79. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures less than 0 degrees Celsius.

80. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures less than −

10 degrees Celsius.

81. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures less than −

20 degrees Celsius.

82. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures less than −

30 degrees Celsius.

83. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures of about −

40 degrees Celsius.

84. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures greater than 175 degrees Celsius during one time period and less than 0 degrees Celsius during another time period.

85. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures greater than 200 degrees Celsius during one time period and less than −

30 degrees Celsius during another time period.

86. The method of claim 47, wherein operating the power system within a temperature range of between about minus forty degrees Celsius and about two hundred and ten degrees Celsius comprises operating the power system at temperatures of about 210 degrees Celsius during one time period and about −

40 degrees Celsius during another time period.

87. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures greater than 150 degrees Celsius.

88. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures greater than 175 degrees Celsius.

89. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures greater than 210 degrees Celsius.

90. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures less than 0 degrees Celsius.

91. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures less than −

10 degrees Celsius.

92. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures less than −

20 degrees Celsius.

93. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures less than −

30 degrees Celsius.

94. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures of about −

40 degrees Celsius.

95. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures greater than 175 degrees Celsius during one time period and less than 0 degrees Celsius during another time period.

96. The method of claim 48, wherein operating the power system comprises operating the power system at temperatures greater than 200 degrees Celsius during one time period and less than −

30 degrees Celsius during another time period.

97. The method of claim 47, wherein operating the power system comprises operating the power system at temperatures of about 210 degrees Celsius during one time period and about −

40 degrees Celsius during another time period.

98. The power system of claim 57, wherein the energy supply comprises at least one of a wireline, a generator, and a battery.

99. The power system of claim 1, wherein the rated voltage is at least 0.1 V.

100. The power system of claim 1, wherein the rated voltage is at least 0.5 V.

101. The power system of claim 1, wherein the rated voltage is at least 4 V.

102. The power system of claim 1, wherein the rated voltage is at least 4 V at room temperature and at least 0.5V at temperatures at or above 210 degrees Celsius.