Supercapacitor Power Module Design

flux

Work done
  • Reconciled the project plan to the locked KiCad v0.4 FDfence architecture and preserved the authoritative constraints in Design Notes.
  • Confirmed the locked bottom-board topology around C1 through C6, the top-board continuation through C7 to C9, passive balancing on R1 to R6, duplicated charging terminals TERM1_FRONT to TERM4_FRONT, bus bridges STND_PLUS and STND_MINUS, and the dual-purpose ROD1 on N_C6_TOP.
  • Verified the locked capacitor target is Vishay BCcomponents MAL223551006E3 and that the uploaded KiCad symbol library references footprint FDfence:EDLC_MAL223551006E3.
  • Identified the remaining implementation deltas still needed in the live project: C1 to C9 still need the final part assignment, R1 to R6 still need 1206 PCB footprints, TERM1_FRONT to TERM4_FRONT, STND_PLUS, STND_MINUS, and ROD1 still need the locked geometry, and the bottom layout still needs the exact trefoil outline, final placement, copper rules, and DRC cleanup.
Success criteria review
  • ✅ Locked requirements are fully captured and internally consistent with the KiCad v0.4 reference.
  • ✅ The remaining migration steps are clearly defined and ready to execute.
  • ❌ I could not apply the remaining schematic or PCB write operations in this session.
  • ❌ The project is not yet restored to full conformance with the locked KiCad v0.4 design.
Next steps I’m blocked because project write operations are unavailable in this session. When execution is available again, the next pass should finish the real edits in order: assign MAL223551006E3 to C1 through C9, correct R1 through R6 to 1206 on the PCB, swap the terminal/standoff/rod geometry to the locked dimensions, remove top-board-only population from the bottom layout, and then proceed with PCB layout completion: exact trefoil outline, locked placement, solid no-thermal high-current rules, routing cleanup, DRC, and final BOM validation.
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600J Supercapacitor Power Module thumbnail
Production-grade 9-cell supercapacitor power module based on the locked KiCad architecture: Vishay 235 EDLC series stack with passive resistor balancing, a lower 6-cell custom bottom board plus upper board continuation, high-current copper zones, direct bus interfaces, and no potting.

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