High Temperature Nano-composite Film Capacitors for Hybrid Electric Vehicles

Future Army ground vehicles are envisioned to use hybrid electric technology. At present, the propulsion systems for these vehicles require power components which are relatively large and inefficient; limiting widespread integration of the technology. DC filter capacitors used in the high frequency power converters consume a substantial portion of the volume in present system designs. Capacitors that provide efficient filtering at high frequencies (up to 100 kHz) with reduced size and increased temperature tolerance are considered essential to advancing hybrid electric technology for the Army. In response to this need, TPL has developed a novel capacitor film technology that meets the need for DC filter capacitors with reduced size and improved operational capability. The Phase I program was successful in defining a nanocomposite dielectric that can provide the necessary specific capacitance (> 0.9 ƒÝF/cm3) and operating temperature capability (> 150„aC). The proposed Phase II effort will be directed at scaled manufacturing and prototype capacitor fabrication. Continuous film fabrication, metallization, winding capabilities will support the planned capacitor development. A unique capacitor design that includes the fault-tolerant nanocomposite film will be pursued and validated relative to operational conditions, efficiency and reliability.