SBIR-STTR Award

A Manufacturing Technology for High Energy Density Diamond-Like Carbon Capacitors
Award last edited on: 10/11/05

Sponsored Program
SBIR
Awarding Agency
DOD : AF
Total Award Amount
$1,964,189
Award Phase
2
Solicitation Topic Code
AF97-198
Principal Investigator
Richard L C Wu

Company Information

K Systems Corporation

1522 Marsetta Drive
Beavercreek, OH 45432
   (937) 429-5151
   rlwu@k-systems-corp.com
   www.k-systems-corp.com
Location: Single
Congr. District: 10
County: Montgomery

Phase I

Contract Number: F33615-97-C-2766
Start Date: 6/23/97    Completed: 3/23/98
Phase I year
1997
Phase I Amount
$99,804
Diamond-Like arbon (DLC) possesses the unique properties of high dielectric strength, high resistivity, high decomposition temperature, chemical inertness, great hardness and good thermal conductivity. In Phase I we demonstrated that DLC films an be deposited directly onto smooth aluminum surfaces with good adhesion, and that DLC Films are highly flexible, making them suitable for the production of wound capacitors. The Phase II research will demonstrate an economical manufacturing technique using a dual ion-gun system with a continuous rolling mechanism for the mass production of rolled capacitors, and will also demonstrate a packaged DLC capacitor of high energy density, smaller size, and lower weight as compared to current film capacitors. The main objective of Phase II will involve the assembly and demonstration of a manufacturing operation which combines the DLC deposition system, the capacitor rolling operation and the capacitor encapsulation processes into a single modular system housed within a 100 square foot area. The whole operation will be assembled within a cleanroom enclosure of no more than 375 square feet. This basic modular fabrication system could then be duplicated for the mass production of capacitors in the Phase III effort.

Benefits:
A manufacturing technology for high energy density wound diamond-like carbon capacitors will be established. The DLC capacitors will have superior high temperature and high voltage performane for electrical power conversion systems. These capacitors will find applications in aircraft and weapon systems as well as in commercial vehicles and aircraft.

Phase II

Contract Number: F33615-98-C-2818
Start Date: 4/17/98    Completed: 9/30/02
Phase II year
1998
Phase II Amount
$1,864,385
Diamond-Like Carbon (DLC) possesses the unique properties of high dielectric strength, high resistivity, high decomposition temperature, chemical inertness, great hardness and good thermal conductivity. In Phase I we demonstrated that DLC films can be deposited directly onto smooth aluminum surfaces with good adhesion, and that DLC Films are highly flexible, making them suitable for the production wound capacitors. The Phase II research will demonstrate an economical manufacturing technique using a dual ion-gun system with a continuous rolling mechanism for the mass production of rolled capacitors, and will also demonstrate a packaged DLC capacitor of high energy density, smaller size, and lower weight as compared to current film capacitors. The main objective of Phase II will involve the assembly and demonstration of a manufacturing operation withch combines the DLC deposition system, the capacitor rolling operation and the capacitor encapsulation processes into a single modeular system housed within a 100 square foot area. The whole operation will be assembled within a cleanroom enclosure of no more than 375 square feet. This basic modular fabrication system could then be duplicated for the mass production of capacitors in the Phase III effort.

Benefits:
A manufacturing technology for high energy density would diamond-carbon capacitors will be established. The DLC capacitors will have superior high temperatue and high voltage performance for electrical power conversion systems. Thes capacitors will find applications in aircraft and weapon systems as well as in commercial vehicles and aircraft