SBIR-STTR Award

Thermally stable, high frequency capacitors are necessary for development of more compact, high power electronics for use in high performance weapons systems. Mechanically and thermally robust capacitors are needed to increase the temperature range and reduce thermal management issues in compact aerospace power conditioning applications. Capacitors can occupy up to 30 percent of the volume in power systems and have been identified as limiting components in high temperature and/or high frequency applications. New dielectric materials and capacitor designs are desired that provide high specific capacitance, high frequency and wide operating temperature capabilities. TPL will develop a novel nanocomposite dielectric film and capacitor technology that is compact, fault-tolerant, and operates at the high temperatures and frequencies needed for aerospace power conversion. TPL has extensive experience in the development of nanocomposite material systems for advanced dielectric properties and associated high performance capacitors. The proposed capacitor is projected to have a packaged specific capacitance of 3 – 6 uF/cc, operating temperature range of -55 to +300 degree C and operational capability up to 100 kHz. The film and capacitor designs will use largely industry standard production methods to facilitate transitions to manufacturing and help control product costs.

Benefit:
The success of this development program will enable the miniaturization of power conditioning modules for advanced aerospace weapons systems. Related DoD benefits can also be realized for power conversion in future Navy all-electric vessels. Commercially, hybrid electric vehicle applications are expected to benefit through higher operating temperature capability, as compared to current capacitor technologies. An additional commercial application will be high power converters for the utility industry, where operating temperature and size are also key concerns. Commercial hybrid electric vehicles are anticipated to represent the greatest commercial opportunity, given the rapid market expansion forecasts and need for high efficiency at elevated temperatures. The global market for hybrid electric cars is presently projected to grow from 0.5 million units in 2008 to more than 11 million units in 2020*. In addition, many heavy-duty truck and bus fleets are being systematically upgraded to hybrid electric drives. Each of these commercial hybrid units will benefit for more compact, higher performance DC filter capacitors. * http://www.autonews.com/article/20090527/ANA05/905279972/1186

Keywords:
Capacitor, Nanocomposite, Wide Temperature, Volumetric Efficiency, Power Conditioning

Electrically driven technologies are replacing hydraulic, pneumatic and mechanical systems in new military aircraft designs to improve capability, reliability and maintainability. This transition requires high performance electronic components capable of operating over a wide temperature range. Capacitors, which provide necessary power conditioning, have been identified as a limiting component for these architectures. New dielectric materials and capacitor designs are needed to provide high specific capacitance and operation at high temperature. TPL completed a successful Phase II program to address this need and demonstrated fundamental proof-of-feasibility for a capacitor design using a novel dielectric film technology. A high dielectric constant capacitor film based on fluorinone polyester (FPE) polymer modified with titanate nanopowder was developed. Thermal and electrical performance characteristics of sub-scale FPE nanocomposite capacitors and packaging materials support a significant advance in high temperature operating capabilities. The proposed Phase II will focus on maturing the capacitor technology and transitioning from the laboratory scale demonstration to commercially produced devices for the Air Force’s high temperature inverter-converter controller. The final product of this transition will include production ready material, processes, designs, and manufacturing capabilities for a state-of-the-art capacitor capable of operating from -55 to 250 °C with an energy density > 1.0 µF/cc.

Benefit:
The success of this development program will enable the miniaturization of electrically driven technologies for future aircraft weapons platforms. Similar benefits can also be realized in commercial hybrid electric vehicle applications, where reduction in size and increased efficiency will offer lower fuel consumption and lighter total weight in vehicles. An additional application for high temperature, compact filter capacitors will be in the utility industry for high power converters, where operating temperature and size are also key concerns. Commercial vehicles are expected to experience the most significant impact overall. The sales of light-duty hybrid electric vehicles are projected to advance to more than 2,000,000 in 2016. In addition, heavy-duty bus and truck fleets are systematically being upgraded to hybrid electric drives. Each of these commercial hybrid units will benefit from higher performance capacitors.

Keywords:
fluorinone polyester