High Voltage, DC-Link Capacitors for Transportable Power Conversion Systems

Transportable energy storage systems are emerging products for grid-tied applications. High voltage pulse power systems are planned for assembly in standard shipping containers to allow for easy transportability. Unfortunately, the current capabilities of these systems are considered inadequate due to the excessive size of the required power souce. Compact, high voltage capacitors are necessary to enable effective development and deployment of power converters for transportable energy storage systems. In response to this need, TPL proposes a development effort and demonstration of a capacitor technology based on a novel dielectric. TPL has developed a polymer film technology that offers capability for a 50% increase in capacitor energy density and a 100% increase in volumetric capacitance, relative to state-of-the-art. The engineered dielectric, referred to as TPL Polymer, is a thermal setting polymer system that has been molecularly designed to achieve unique dielectric properties for high energy storage density. Pilot-production scale film and prototype capacitor manufacturing capabilities have recently been established for TPL polymer. The Phase I effort will include the design, development and fabrication of wound film capacitors using TPL Polymer to assess its suitability in high voltage, DC-link capacitors for power conversion systems. Established polymer chemistry, film fabrication, film metallization and prototype capacitor construction will be applied to custom DC-link capacitor designs. The prototype capacitors will be subjected to a series of application specific DC and ripple performance tests and evaluated with respect to current state-of-the-art capacitor technology. Success in this development program will facilitate the deployment of high voltage power conversion systems for transportable energy storage systems. Successful development will also benefit other high voltage applications such traction motors and pulse power supply systems. Success in this development program will facilitate the miniaturization and added power capabilities for advanced transportable power systems. Successful development will also benefit other high voltage applications such traction motors, pulse power supply systems and medical systems.