Wide Temperature, High-Frequency Capacitors for Aerospace Power Conditioning Applications

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