SBIR-STTR Award

Multi-point initiators used in modern explosive projectiles rely on high voltage capacitors which can deliver high power in a low inductance configuration. Current capacitors meeting the required performance specifications are based on dielectric ceramics in multi-layer configurations. These capacitors cost as much as $100 and have a volume of over 400 mm3. This translates to $200-400/J/cm3, consequently, the use of multi-point initiators for many ARDEC applications is limited by size and cost of these capacitors. In response to this need, TPL proposes development of a revolutionary capacitor technology based on high energy density polymer-nanoparticle dielectrics. Previous work by TPL has defined a nanocomposite material system with an intrinsic energy density capability that exceeds conventional dielectrics by an order of magnitude. Further, the dielectric can be processed as a polymer and is compatible with low cost circuit board manufacturing processes. The proposed program will be directed at establishing manufacturing processes for multi-layer nanocomposite capacitors with form factor similar to conventional capacitors but with significantly reduced size and cost. Phase I objectives include a detailed design, cost analysis and proof of concept demonstration for capacitors with two orders of magnitude reduction in cost/energy density, $1-4/J/cm3.

Multi-point initiators used in modern explosive projectiles rely on high voltage capacitors which can deliver high power in a low inductance configuration. Current capacitors meeting the required performance specifications are based on dielectric ceramics in multilayer configurations. These capacitors cost as much as $100 and have a volume of over 0.4 cc. This translates to $200-400/J/cc, consequently, the use of multi-point initiators for many ARDEC applications is limited by size and cost of these capacitors. In response to this need, TPL Inc., with support from Sandia National Laboratories, proposes the continued development of a revolutionary capacitor technology based on high energy density polymer-nanoparticle dielectrics. Phase I program was successful in defining materials and designs capable of two orders of magnitude improvement in the cost/energy density performance of multi-point initiator capacitors. Proof of concept was demonstrated in subscale capacitors which can be efficiently transitioned to production. The Phase II effort will be directed at transition of the capacitor technology to a low-cost manufactureable product. TPLs capabilities for producing wound polymer film capacitors will be applied to the fabrication of nanocomposite capacitors with form factor similar to conventional multilayer capacitors but with two orders of magnitude reduction in cost/energy density, $1-4/J/cc.