Improved Manufacturing Processes for Advanced Capacitors

This Small Business Innovation Research Phase I project addresses improving manufacturing methods and performance of an all-solid high energy/power density high-voltage capacitor packaged in a low-cost, bipolar multi-cell configuration. These devices can be used in a wide range of portable electronic systems especially in demanding industrial, defense and aerospace applications. The Phase I program will demonstrate a novel and inexpensive method for manufacturing multi-cell capacitors, which are expected to have advantages resulting in sustainable cost and volume savings compared to current capacitors. Substitution of a solid polymer electrolyte for liquid electrolyte will result in a device that is much easier to fabricate and manufacture without the possibility of electrolyte leakage, thereby enhancing reliability, life and safety features. Successful completion of this Phase I program would demonstrate the manufacturing viability of a new class of capacitors that offers a more durable solution for high efficiency, high reliability and low cost storage capacitors for applications currently occupied by aluminum, ceramic, and tantalum capacitors. Phase I will identify methods of simplifying packaging and manufacturing processes, as well as improving the energy density and reducing the capacitor size. High-voltage capacitor units will be fabricated and characterized to demonstrate the feasibility of our approach.