Supercapacitors are helping to reshape the landscape for embedding electronics into clothing for all kinds of functionality. The OptiXtal 800 mF super capacitor is less than 1 mm thick and fits in a 17x22 mm footprint. It is able to withstand multiple washing and drying cycles. A major athletics supplier requires that a 5 F super cap combination be able to recharge wirelessly within 15 seconds, power a device for 90 minutes and do that in a foot print of 17x 45 mm and less than 4 mm thick.

Given these constraints, Optixtal has designed a side by side pairing of our 17x22 mm superap in a stack of three pairs to deliver a less than 4 mm thick footprint that contains the total capacitance and recharge speed required, all in a package able to survive multiple hot washings and dryers in commercial laundries.

Medical Implantable Devices

Pacemakers, hearing aids, wrist-based monitors – all require robust batteries for long lasting power. Supercaps, coupled with new energy harvesters, enable the rethinking of medical device technologies. Battery replacement for an implanted medical device is both costly and dangerous to the health of the patient. Creating an easily rechargeable, through-the-skin energy storage unit able to last 20+years of daily recharge cycles is the answer to invasive surgery to replace batteries.

Optixtal has worked closely with client engineers to create a supercap that is both thin and which can deliver the required capacitance, all within a small footprint. Microwaves able to pass through the skin are used to recharge the super cap that powers the unit. The unit has a 20+year life requirement with the ability to flawlessly support 100,000+ charge/discharge cycles.

Remote Fire Sensor

Battery replacement continues to be a maintenance restraint. Powering active communications from sensor to base often requires direct power. Our client developed an ambient light-powered fire sensor with Optixtal super cap as the power source. Our product is able to capture and store the energy harvested by the solar panel and deliver that energy efficiently to power the sensor and an active wireless communication to a base server. Shape, thinness and minimal leakage were critical factors addressed by OptiXtal.

The compactness of the sensor’s design required a form fitting, flexible rectangular shape. Leakage requirements were significantly high than typically found among competitive super cap. Once energy was harvested from the environment, the client had little tolerance for having that energy lost to leakage.

Extending Battery Life of eRickshaw

Through this application, Optixtal marries old-line lead acid technology with cutting edge supercapacitors and software to deliver superior performance. E-rickshaws in India are each powered by four lead acid batteries with a range of 80-90 kilometers. Batteries require replacement every six months, creating a significant financial burden on e-rickshaw owners. Optixtal is solving this problem by increasing the life of the lead acid batteries by a factor of three and increasing the range by 20%.

This will significantly reduce the cost to operate an e-rickshaw. In addition, Optixtal has created a superior battery management system, using a combination of software, hardware, and supercapacitors, which diverts the peak load demands off of the batteries. This improves the range of the battery between charges and adds to the overall life of the battery.

By changing the charging patterns, the Optixtal solution can safely recharge the lead acid batteries in 3-4 hours versus the typical 6-8 hours. All in all, our solution can lead to improved performance, faster recharge cycles, and extended battery life.